Webasto Thermo Top E Installation Instructions Manual

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

Validity Vehicle and engine types, equipment variants and national specifications not listed in these installation instructions have not been tested. However, installation according to these installation instructions 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

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

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 Webas- to components or to the manufacturer's vehicle-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.

- 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 1 Heater unit Installa- tion loca- tion 1 1

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 (4 mm²) 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 Insulate and tie back ends of red/white (rt/ws) wire 5 and 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 1 to K3/85 and to K3/87. Preparing K3 relay Strip insulation from approx. 500 mm of wiring harness of digital timer 3. Detach 0.75² brown (br) wire 1 from 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 4 3 3 5 2 4 1 3 2

Before installing, crimp 8 mm dia. cable lug onto positive wire. 1 Red (rt) wire 2 Original 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 2 and route into passen- ger compartment. Wiring har- ness in- stallation diagram Fuse holder, K3 relay 1 Retaining plate for fuse holder 2 4 mm dia. hole, 5.5x13 self-tapping screw; plastic nut [2x each] 3 K3 relay 4 Fuse holder Connecting ground wire 1 Brown (br) wire 2 Original vehicle ground support point 5 1 2 6 1 2 Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the under- body 7 4 2 1 2 3 8 2 1

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 2 Heater control connector br brown sw black Insulate wire ends and tie back Cable and connector colors may vary! View of BSI. 1 Socket 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 6 St A 86 85 30 87a 87 K3 1 HG X1 4 2 9 1 1

2 20-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 1 in 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

tion. Agree upon with final customer before installing. 1 Digital timer Installing digital tim- er Remote option (Telestart) Fasten receiver 2 with adhesive tape onto cross member 1! Installing receiver 1 Antenna Installing antenna Temperature sensor for HTM100 only 1 Fasten temperature sensor with adhesive tape Installing tempera- ture sensor 1 12 13 1 2 14 1 1 15

carried out if bracket provided does not match current state! Drill 7 mm dia hole 1 and 3 in bracket 2. Drilling bracket Drill 7 mm dia. hole 2 in bracket 1. Drilling bracket Drill 7 mm dia. hole 1 and 2 in bracket 3. Drilling bracket 1 Bracket 2 Angle bracket,M6x16 bolt, large diameter washer, nut [2x each] Premount- ing bracket 16 2 12 8 26 3 1 17 2 1 12 8 18 1 70 23 20 2 3 19 2 2 1

tance to bracket of ABS 3 and 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 1 Rivet nut [4x] Installing rivet nut 1 M6x20 bolt, spring lockwasher [2x each] 2 Bracket Installing bracket 20 1 3 35 2 2 21 1 1 22 1 1 1 1 23 1 1 2

[2x each] Installing bracket Installing heater unit 1 Ejot screws [2x] 2 Heater unit Installing heater unit 1 Ejot screw Installing heater unit 24 1 1 25 1 1 2 26 1

a = 360 Discard section X Cutting combus- tion air pipe to length 1 Cable tie 2 Combustion air pipe 3 27 mm dia. clamp 4 Muffler Installing combus- tion air pipe and muffler a 1 X 27 1 2 3 1 4 1 1

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. Route fuel line 1, together with wiring harness 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. 2 Hose section, 10 mm dia. clamp [2x] Connec- tion to heater unit 1 Fuel line from heater unit 2 Line duct 3 Metering pump wiring harness Installing lines 1 Angle bracket 2 Silent block, flanged nut [2x] 3 Rubber-coated pipe clamp 4 Metering pump 5 Original vehicle bolt Installing metering pump 28 2 1 29 1 2 3 30 1 2 5 3 4

if necessary. Check that they have free clear- ance. 1 Wiring harness of metering pump, connec- tor mounted 2 Fuel line from heater unit 3 Hose section, 10 mm dia. clamp [2x] Connect- ing to me- tering pump Remove fuel-tank sending unit 1 in accor- dance with manufacturer's specifications. 2 5 mm dia. large diameter washer 3 Copy hole pattern, 6 mm dia. hole Removing fuel Shape fuel standpipe 1 according to tem- plate, cut to length and install. Installing fuel stand- pipe Install fuel-tank sending unit 3 in accordance with manufacturer's instructions. 1 Fuel line 2 Hose section, 10 mm dia clamp [2x] Connect- ing fuel line 31 1 2 3 32 1 2 3 33 1 1 34 1 2

if necessary. Check that they have free clear- ance. 1 Hose section, 10 mm dia. clamp [2x] 2 Fuel line Connect- ing to me- tering pump 35 1 2

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

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. 1 50 mm long heat shrink plastic tubing [4x] Preparing coolant hoses Cut off original vehicle hose on engine out- let/heat exchanger inlet at marking. If present, remove original vehicle braided protection hose. 1 Engine-outlet hose section 2 Hose 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

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

a = 240 2 Exhaust end section b = 240 Preparing exhaust pipe Bend perforated bracket 1 by approx.90°. Preparing perforated bracket 1 Exhaust muffler 2 Ejot screw 3 Perforated bracket, M6x20 bolt, flanged nut Installing exhaust muffler Ensure sufficient distance to adjacent compo- nents; correct if necessary. 1 Hose clamp [3x] 2 Exhaust pipe 3 Exhaust end section Installing exhaust pipe and end sec- tion a b 1 2 X 50 65 41 1 42 3 1 2 43 1 1 2 1 3

2 42 mm dia. hole Cutting out underride protection Align exhaust end section 1 flush on red rub- ber isolator 2. Mounting rubber iso- lator 44 1 2 65 35 2 45 1

01/2010 Printing: Stef- fen 1314514A_EN Feel the drive Webasto AG Postfach 80 D-82131 Stockdorf / Germany National Hotline: 01805 93 22 78 (14 Cent aus dem deutschen Festnetz) Hotfax: 0395 5592 353 Hotmail: [email protected] http://www.webasto.de Final Work WARNING! Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Secure all loose cables using cable ties. Only use manufacturer-approved coolant. Spray heater unit components with anti-corrosion wax (Tectyl 100K, Order No. 111329). - Connect the battery. - Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications. - Set the digital timer. - Check the proper operation of the additional heater, see the operating instructions/installation in- structions. - Attach the „Switch off additional heater before refueling“ sticker near the filler neck Coding BSI Central switching unit The BSI central switching unit has to be configured as follows: Select the vehicle >3008< Special equipment Additional heater retrofitted Installation of the accessories additional heater Additional heater retrofitted Confirm to continue Select the application >Peugeot Planet 2000< Confirm to continue

lines. Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimize mar- gins” and 100% of the normal size. Template for Fuel Standpipe

Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min. On vehicles with anti-theft alarm, the passenger compartment monitoring system must be deactivated. For information on deactivation, please see the vehicle owner's manual. There are no further settings to be made on the vehicle!