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

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

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-

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

Do not install themetering pump

cableharnessuntillatertogether

with fuel pipe along the original

vehicle fuel lines on the under-

body

21 2

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

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

Peugeot

0,5²

0,75²

gn/ws

rt/

BSI

6St A

85 30

87a87

X1 4

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

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-

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 2

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