Webasto Thermo Top E User manual

Water Heater Unit
Installation Instructions
Ident. No.:1315210A_EN Fee Euro 10.00 © Webasto AG
Peugeot 3008
Diesel
from Model Year 2009
Left-hand drive vehicle
Manual transmission
Automatic air-conditioning
Feel the drive
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.
Only genuine Webasto parts may be used. See also Webasto air and water heaters acces-
sories catalogue.
NEVER attempt to install or repair Webasto heating or cooling systems if you have not
successfully completed the company training and thereby acquired the required tech-
nical skills, or if you do not have access to the required technical documentation, tools
and equipment needed to carry out correct installation and repairs.
ALWAYS follow all Webasto installation and repair instructions and observe all warnings.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Thermo Top E Additional Heater e1
00 0003
Thermo Top C Additional Heater
e1
00 0002
Thermo Top P Additional Heater e1
00 0104

Peugeot 3008
1315210A_EN 2
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However,installation according to these installationinstructions may
be possible.
The installation location of the digital timer should be confirmed with the end customer before installa-
tion.
Manufacturer Model Type EG-BE No./ABE
Peugeot 3008 OU e2 * 2001 / 116 * 0377 * ...
Engine type Engine model Output in kW Displacement in cm³
RHE Diesel 110 1997
Validity 2
Heater Unit/Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater unit installation location 5
Preparing electrical system 6
Electrical system 7
Fan controller 8
Remote option (Telestart) 10
Preparing installation location 11
Installing heater unit 12
Coolant circuit 13
Fuel 17
Combustion air 20
Exhaust gas 21
Final Work 23
Coding BSI Central switching unit 23
Operating Instructions for End Customer 24

Peugeot 3008
1315210A_EN 3
Heater Unit/Installation Kit
Heater unit recommended for the respective vehicle class:
The selection of the heater unit is based on the passenger compartment size of the vehicle and the
level of comfort required by the customer!
Foreword
These installation instructions apply to Peugeot 3008 Diesel vehicles - for validity, see page 2 - from
model year 2009 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,thestipulations in the "installationinstructions"and"operating and maintenanceinstructions"
for the Thermo Top C/P/E must always be observed.
The corresponding rules of technology and any information from the vehicle manufacturer should be
observed during the installation work.
General Instructions
Installation should be carried out according to the general, standard rules of technology. Unless spec-
ified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses
using cable ties.
Sharp edges must be provided with rub protection (cut-open fuel hose)!
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No.
111329).
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Metric thread-setter kit
Quantity Description Order No.:
1 Retail accessories Thermo Top E / C / P See price list
1 Installation kit for Peugeot 3008 2009 Diesel 1315209A
1 Heater control See price list
Vehicle Heater Unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

Peugeot 3008
1315210A_EN 4
Special features are highlighted using the following symbols:
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.
ReferencetogeneralinstallationinstructionsofWebas-
tocomponentsortothemanufacturer'svehicle-specific
documents.
Reference to a special technical feature.
All dimensions are in mm!
Tightening torque of hose clamps = 2.0 + 0.5 Nm!
Tightening torque of Ejot screws, Ejot studs = 10 Nm!
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
Software
Explanatory Notes on 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 3008
1315210A_EN 5
Preliminary Work
WARNING!
- Disconnect the battery "earth" or "ground" connection.
- Depressurize 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.
- Open the fuel tank cap and vent the fuel tank.
- Close the tank cap again.
- Remove engine design cover
- Remove air filter box
- Remove charge-air tube with bracket (bolts will be reused)
- Completely remove the battery and the battery carrier.
- Remove front underride protection
- Remove the right rear underride protection.
Remove page 24 "Operating Instructions for End Customer" and add to vehicle operating instructions!
Heater unit installation location
1Heater unit
Installa-
tion loca-
tion
1
1

Peugeot 3008
1315210A_EN 6
Preparing electrical system
Cut off black (sw) wire 5(0.75 mm²) from wir-
ing harness of heater unit. Cut off red/white
(rt/ws) wire 6(4 mm²) of fuse F3. Remove in-
sulation from ground wires to node point and
cut off brown (br) wire 4(0.75 mm²) from wir-
ing harness of digital timer.
Remove red/white (rt/ws) wire 1(4mm²) from
K3/87, red (rt) wire 3(4 mm²) from K3/87a
and black (sw) wire 2(4 mm²) from K3/30.
Preparing
fuse F3
and K3 re-
lay
Insulateandtie back ends of red/white(rt/ws)
wire 5and black (sw) wire 4. Insulate ground
wires 3.
Insert brown (br) wire 2(0.75 mm²) from wir-
ing harness of heater controls in K3/30.
Also connect black (sw) wire 1to K3/85 and
to K3/87.
Preparing
K3 relay
Stripinsulationfromapprox.500mmofwiring
harnessofdigitaltimer 3. Detach0.75² brown
(br) wire 1from wiring harness, crimp on mi-
crotimer and then re-insulate remaining
wires! Preparing
wiring har-
ness of
digital tim-
er
3
6
1
2
5
2
4
1
43
3
5
2
4
1
3
2

Peugeot 3008
1315210A_EN 7
Electrical system
Positive and ground wire
1Positive red (rt) wire on original vehicle posi-
tive support point
2Brown (br) ground wire on original vehicle
ground support point
Digital timer
1Digital timer
Wiring har-
ness in-
stallation
diagram
Fuse holder, K3 relay
1Retaining plate for fuse holder
24 mm dia. hole, 5.5x13 self-tapping screw;
plastic nut [2x each]
3K3 relay
4Fuse holder
Wiring harness pass through
Route wiring harnesses (digital timer, fan control-
ler and green/white (gn/ws) wire in protective
sleeving) on original vehicle wiring harness 1 to
protective rubber plug 2and route into passen-
ger compartment.
5
1
2
6
1
Do not install themetering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
7
4
1 2
3
2
8
1
2

Peugeot 3008
1315210A_EN 8
Fan controller
Wiring dia-
gram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E BSI Central electrical
box for passenger
compartment
gn green
K3 Fan relay ws white
1
Wiring harness of digital timer St A 20-pin connector
BSI rt red
2Heater control connector br brown
sw black
Insulate wire ends and tie
back
Cable and connector colors may vary!
View of BSI.
1Socket for 2-piece connector. 40-pin
Detaching
BSI and
routing
downward
Webasto
31
30
15
Peugeot
0,5²
br
0,75²
br
0,75²
!
gn/ws
br
rt/
ws
sw
BSI
6St A
86
85 30
87a87
K3
1
HG
X1 4
2
9
1
1

Peugeot 3008
1315210A_EN 9
Press in locking lug 1and fold down bar 3.
220-pin blue connector
Pulling
connector
off BSI and
removing
Connection on 20-pin blue (bl) connector 2
from BSI. Insert microtimer from brown (br)
wire 1in PIN 6. Complete BSI connector and
mount.
Route wiring harness of digital timer upward
to installation location of digital timer.
Produce connections as shown in wiring dia-
gram.
Connec-
tion of BSI
10
1
2
3
11
2
1

Peugeot 3008
1315210A_EN 10
Remote option (Telestart)
Fasten receiver 2with adhesive tape onto
cross member 1!
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor for HTM100 only
1Fasten temperature sensor with adhesive
tape
Installing
tempera-
ture sensor
12
1 2
13
1
1
14

1315210A_EN 11
Peugeot 3008
Preparing installation location
1Bracket of Part A
2M6x12 bolt, flanged nut [2x each]
3Bracket of Part B Preparing
bracket
Loosely install bracket (A and B) 5and brack-
et of charge-air tube 2.
1M6x16 bolt, spring lockwasher, large diam-
eter washer on existing threaded hole
3Original vehicle bolt
4Copy hole pattern Copying
hole pat-
tern
Remove bracket (A+B) and bracket of
charge-air tube!
1Drill 9.1 mm dia. hole; rivet nut
Installing
rivet nut
Mount bracket of charge-air tube 2with origi-
nal vehicle bolts 3. Insert M8x15 spacer nut
between bracket (B) and frame side member
at position 4.
1M6x16 bolt, spring lockwasher, large diam-
eter washer on existing threaded hole
4M6x30 bolt, spring lockwasher, M8x15
spacer nut
Installing
bracket
15
1
3
2 2
16
1
45
2
3
17
1
18
1
4
2
3
3

1315210A_EN 12
Peugeot 3008
Installing heater unit
1Bracket of charge-air tube
2Charge-air tube
Installing
charge-air
tube
1Ejot screw [2x]
Installing
heater unit
Ensure sufficient distance to charge-air
tube 2!
1Ejot screw
Installing
heater unit
1Wiring harness of heater unit
Connect-
ing wiring
harness
19
2
1
20
1
1
21
1
2
22
1

Peugeot 3008
1315210A_EN 13
Coolant circuit
WARNING!
Any coolant running off should be collected using an appropriate container!
Route coolant hoses kink-free! Unless specified otherwise, always fasten using cable ties.
Position clamps so that no other hose can be damaged!
When installing the coolant hose, the heater unit must be filled with coolant.
The connection should be "inline" based on the following diagram:
Coolant
routing di-
agram
All hose clamps = 20-27 mm dia.!
All connecting pipes without a specific designation = dia. 18x20.
1= Black (sw) rubber isolator .
C
D
A
1
B
1
Ø 18x18
Ø 20x20

Peugeot 3008
1315210A_EN 14
Hose A= 180° (18x18) molded hose
Discard section X
B=630
C=130
D=500 Cutting
coolant
hoses to
length
Push braided protection hoses onto hose B
and Dand cut to length.
Cut heat shrink plastic tubing to length and
shrink to size.
150 mm long heat shrink plastic tubing [4x] Preparing
coolant
hoses
Remove original vehicle hose on engine out-
let/heat exchanger inlet 1.
Cutting
point
Remove braided protection hose in area of
cutting point 2. Remount hose section of heat
exchanger inlet 1 and hose section engine
outlet 3!
Separating
hose
C
B
X
D
15 X
A
X
B
D
1 1
1
1
23
1
24
2 13

Peugeot 3008
1315210A_EN 15
7 mm dia. hole at position 2in original vehicle
bracket 1!
3M6x20 bolt, flanged nut
448 mm dia. rubber-coated p-clamp Installing
p-clamp
Connect-
ing heater
unit outlet
Route hose D through 48 mm dia. rubber-
coated p-clamp 1.
Routing in
engine
compart-
ment
1Hose on heat exchanger inlet
2Insert spacer bracket
Connect-
ing heat
exchanger
inlet
25
3
4
1
2
26
C
D
27
D
1
28
D
1
2

Peugeot 3008
1315210A_EN 16
Push black (sw) rubber isolator 1ontohose B
and align on charge-air tube.
Connect-
ing heater
unit inlet
Route hose B through 48 mm dia. rubber-
coated p-clamp 1.
Routing in
engine
compart-
ment
Push black (sw) rubber isolator 2onto
hose B.
1Engine-outlet hose section
Connect-
ing engine
outlet
Mount black (sw) rubber isolator 2to original
vehicle bracket 4. Ensure sufficient distance
to adjacent components; correct if necessary.
1Cable tie [2x]
2Insert spacer bracket Connect-
ing engine
outlet
29
1
b
30
b
1
31
1
a
b
2
32
2
1
1
4
3

Peugeot 3008
1315210A_EN 17
Fuel
CAUTION!
Open the vehicle's fuel tank cap, 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 wiring harness so that they are protected against stone impact.
Unless specified otherwise, always fasten using cable ties.
Mount the fuel line and wiring harness with rub protection on sharp edges.
WARNING!
The fuel line and wiring harness are routed to the metering pump in as shown in the wiring harness
routing diagram.
Route fuel line 1in 2,100 mm corrugated
tube to firewall.
2Hose section, 10 mm dia. clamp [2x]
Connec-
tion on
heater unit
Separate corrugated tube at position 1.
Routefuellinetogetherwithwiringharnessof
metering pump 2in corrugated tube to right-
hand side of vehicle.
Installing
lines
Route fuel line and wiring harness of meter-
ing pump 1in corrugated tube along original
vehicle fuel lines in line duct to underbody.
Installing
lines
33
1 2
34
1
2
35
1

Peugeot 3008
1315210A_EN 18
Route fuel line and wiring harness of meter-
ing pump 2in corrugated tube to installation
location of metering pump.
1Line duct Installing
lines
Angle down perforated bracket 1by approx.
85° and drill out to 8.5 mm dia. at position 2.
Preparing
perforated
bracket
1Perforated bracket
2Silent block, flanged nut [2x]
3Rubber-coated pipe clamp
4Metering pump
Preparing
metering
pump
1Perforated bracket
2Original vehicle stud bolt, original vehicle
nut
Installing
metering
pump
36
1
2
37
70
75
1
2
38
4
1
2
3
39
1 2
5 4

Peugeot 3008
1315210A_EN 19
1Wiring harness of metering pump, connec-
tor mounted
2Fuel line from heater unit, hose section,
10 mm dia. clamp [2x]
Connect-
ing to me-
tering
pump
Cut off fuel supply line 3at Position 2.
1Hose section, 10 mm dia. clamp [2x]
28x5x8 fuel standpipe, 10 mm dia. clamp
[2x] Removing
fuel
Push fabric protective hose 2onto fuel line of
T-piece 3. Check the position of the compo-
nents; adjust if necessary. Check that they
have free clearance.
1180° molded hose, 10 mm dia. clamp [2x] Connect-
ing to me-
tering
pump
40
1
2
41
1
3
2
42
1
2
3

Peugeot 3008
1315210A_EN 20
Combustion air
1Combustion air pipe
a = 320
Discard section XCutting
combus-
tion air
pipe to
length
127 mm dia. clamp
2Combustion air pipe
Installing
combus-
tion air
pipe
Remove rubber coating from p-clamp
1P-clamp 48 mm dia. hole
2M6x20 bolt, flanged nut, existing hole
3Muffler
4Combustion air pipe Installing
muffler
a
1
X
43
1
2
44
2
4
3
1