Webasto Thermo Top E User manual

Water Heater Unit
Installation Instructions
Ident. No.:1314514A_EN Fee Euro 10.00 © Webasto AG
Peugeot 3008
Gasoline
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
1314514A_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
5FW Gasoline 88 1598
5FX Gasoline 110 1598
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
Digital timer 10
Remote option (Telestart) 10
Preparing bracket 11
Installing bracket 12
Installing heater unit 13
Combustion air 14
Fuel 15
Coolant 18
Exhaust gas 21
Final Work 23
Coding BSI Central switching unit 23
Template for Fuel Standpipe 24
Operating Instructions for End Customer 25

Peugeot 3008
1314514A_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 Gasoline 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, the stipulations in this "installation instructions" and the "operating and maintenance instruc-
tions" 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 Peugeot 3008 Gasoline ACC 1314513A
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
1314514A_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
Fuel
Exhaust gas
Combustion air
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
1314514A_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 the engine cover (depending on the vehicle equipment, if installed)
- Remove the air filter box with the intake hose and the resonator.
- Remove the bracket for the resonator.
- Completely remove the battery and the battery carrier.
- Remove the left front wheel.
- Remove the underride protection.
- Remove the left-hand wheel well trim.
- Detach the right rear bench seat and fold up
- Open the right-hand fuel sender service lid.
- Remove the fuel-tank sending unit in accordance with the manufacturer's instructions.
- Remove the lower instrument panel trim on the driver's side.
Remove page 25 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater unit installation location
1Heater unit
Installa-
tion loca-
tion
1
1

Peugeot 3008
1314514A_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
1314514A_EN 7
Electrical system
Connecting positive wire
Before installing, crimp 8 mm dia. cable lug onto
positive wire.
1Red (rt) wire
2Original vehicle positive support point
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.
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
Connecting ground wire
1Brown (br) wire
2Original vehicle ground support point
5
1
2
6
1
2
Do not install themetering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
7
4
21 2
3
8
2
1

Peugeot 3008
1314514A_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
1314514A_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
1314514A_EN 10
Digital timer
Installation location shown is a recommenda-
tion. Agree upon with final customer before
installing.
1Digital timer Installing
digital tim-
er
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
1
12
13
1 2
14
1
1
15

1314514A_EN 11
Peugeot 3008
Preparing bracket
The following work, Figure 16-18, must be
carriedoutifbracketprovideddoesnotmatch
current state!
Drill 7 mm dia hole 1and 3in bracket 2.Drilling
bracket
Drill 7 mm dia. hole 2in bracket 1.
Drilling
bracket
Drill 7 mm dia. hole 1and 2in bracket 3.
Drilling
bracket
1Bracket
2Angle bracket,M6x16 bolt, large diameter
washer, nut [2x each]
Premount-
ing bracket
16
2
12
8
26
3
1
17
21
12
8
18
1
70
23 20 2
3
19
2
2
1

1314514A_EN 12
Peugeot 3008
Installing bracket
Align bracket 1, maintain approx. 2-3 mm dis-
tance to bracket of ABS 3and copy hole pat-
tern 2[2x] for 9.1 mm dia. hole. Copying
hole pat-
tern
Copy hole pattern 1 [2x] for 9.1 mm dia. hole.
Copying
hole pat-
tern
1Rivet nut [4x]
Installing
rivet nut
1M6x20 bolt, spring lockwasher [2x each]
2Bracket
Installing
bracket
20
1
3
35
22
21
1 1
22
11
11
23
11
2

1314514A_EN 13
Peugeot 3008
1M6x20bolt, springlockwasher,flanged nut
[2x each]
Installing
bracket
Installing heater unit
1Ejot screws [2x]
2Heater unit
Installing
heater unit
1Ejot screw
Installing
heater unit
24
11
25
1 1
2
26
1

Peugeot 3008
1314514A_EN 14
Combustion air
1Combustion air pipe
a = 360
Discard section XCutting
combus-
tion air
pipe to
length
1Cable tie
2Combustion air pipe
327 mm dia. clamp
4Muffler
Installing
combus-
tion air
pipe and
muffler
a
1
X
27
12
3
1
4
1 1

Peugeot 3008
1314514A_EN 15
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. Un-
less 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.
Routefuelline 1,togetherwithwiringharness
of metering pump to firewall on right-hand
side of vehicle and further in line duct on un-
derbody to installation location of metering
pump.
2Hose section, 10 mm dia. clamp [2x] Connec-
tion to
heater unit
1Fuel line from heater unit
2Line duct
3Metering pump wiring harness
Installing
lines
1Angle bracket
2Silent block, flanged nut [2x]
3Rubber-coated pipe clamp
4Metering pump
5Original vehicle bolt Installing
metering
pump
28
2
1
29
1
2
3
30
1 2
5
3
4

Peugeot 3008
1314514A_EN 16
Check the position of the components; adjust
if necessary. Check that they have free clear-
ance.
1Wiring harness of metering pump, connec-
tor mounted
2Fuel line from heater unit
3Hose section, 10 mm dia. clamp [2x]
Connect-
ing to me-
tering
pump
Remove fuel-tank sending unit 1in accor-
dance with manufacturer's specifications.
25 mm dia. large diameter washer
3Copy hole pattern, 6 mm dia. hole Removing
fuel
Shape fuel standpipe 1according to tem-
plate, cut to length and install.
Installing
fuel stand-
pipe
Install fuel-tank sending unit 3in accordance
with manufacturer's instructions.
1Fuel line
2Hose section, 10 mm dia clamp [2x] Connect-
ing fuel
line
31
1
23
32
1
2
3
33
1
1
34
1
2

Peugeot 3008
1314514A_EN 17
Check the position of the components; adjust
if necessary. Check that they have free clear-
ance.
1Hose section, 10 mm dia. clamp [2x]
2Fuel line Connect-
ing to me-
tering
pump
35
1
2

Peugeot 3008
1314514A_EN 18
Coolant
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 .
B
C
A
Ø 20x20 1

Peugeot 3008
1314514A_EN 19
Hose A=180° molded hose
Shorten hose B. Discard section X
B= 650
C= 630 Cutting
coolant
hoses to
length
Push braided protection hoses onto hose B
and C and 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
Cut off original vehicle hose on engine out-
l e t / h e a t e x c h a n g e r i n l e t a t m a r k i n g .
If present, remove original vehicle braided
protection hose.
1Engine-outlet hose section
2Hose section of heat exchanger inlet Cutting
point
Connect-
ing heater
unit
C
B
X
X
A
B
C
1 1
1
1
36
1
2
37
C
b

Peugeot 3008
1314514A_EN 20
1Cable tie [2x]
2Black (sw) rubber isolator fastened with ca-
ble tie
3Edge protection 50
Routing
1Engine-outlet hose section
2Cable tie
Connect-
ing engine
outlet
Ensure sufficient distance to adjacent compo-
nents; correct if necessary.
1Hose section of heat exchanger inlet
Connect-
ing heat
exchanger
inlet
38
3
b
b
2
1
1
39
12
b
a
40
C
1