Water Heater

E1
Thermo Top Evo Parking Heater 00 0258

Installation Documentation
Peugeot 3008 / 5008
Validity
Manufacturer Model Type EG-BE No. / ABE
Peugeot 3008 0U e1 * 2001 / 116 * 0377 * ...
Peugeot 5008 0 e2 * 2007 / 46 * 0004 * ...

Motorisation Fuel Transmission type Output in kW Displacement in cm³ Engine code

1.6 HDI Diesel SG 82 1560 9HR

SG = Manual transmission

From Model Year 2011

Left-hand drive vehicle

Verified equipment variants: Automatic air-conditioning

Front fog light

Not verified: Passenger compartment monitoring

Total installation time: approx. 8 hours

Ident. No.: 1318133B_EN Status: 08.01.2013 © Webasto Thermo & Comfort SE

Peugeot 3008 / 5008

Table of Contents
Validity 1 Preparing Heater 14
Necessary Components 2 Preparing Installation Location 14
Installation Overview 2 Installing Heater 15
Information on Total Installation Time 2 Fuel 17
Information on Operating and Installation Instructions 3 Combustion Air 20
Information on Validity 4 Exhaust Gas 22
Technical Information 4 Preparing Wiring Harness of Circulating Pump 24
Explanatory Notes on Document 4 Coolant Circuit 25
Preliminary Work 5 Final Work 32
Heater Installation Location 5 Template of Bracket Hole Pattern 33
Preparing Wiring Harnesses 6 Template for Fuel Standpipe 34
Electrical System 8 Operating Instructions for Automatic Air-Conditioning 35
Wiring Harness Routing 9
Fan Controller 11
Digital Timer 13
Remote Option (Telestart) 13

Necessary Components

• Basic delivery scope Thermo Top Evo in accordance with price list

• Installation kit for Peugeot 3008 / 5008 2011 1.6 Diesel: 1318132A

• Heater control in accordance with price list and upon consultation with end customer

• In case of Telestart, indicator lamp in accordance with price list and in consultation with end
customer

Installation Overview

1 5

Legend:

3
1. Heater
2. Engine compartment fuse 4
holder
3. Circulating pump
4. Digital timer
2
5. Metering pump

Information on Total Installation Time

The total installation time includes the time needed for mounting and demounting of the vehicle-specific components,
the heater specific installation time and all other times required for the system integration and initial start-up of the
heater.
The total installation time may vary for vehicle equipment other than provided.

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Peugeot 3008 / 5008

Information on Operating and Installation Instructions

1 Important Information (not complete) Beginning of excerpt.
1.1 Installation and Repair ANNEX VII
The improper installation or repair of Webasto heating and cooling sys- REQUIREMENTS FOR COMBUSTION HEATERS
tems can cause fire or the leakage of deadly carbon monoxide, leading AND THEIR INSTALLATION
to serious injury or death.
1. GENERAL REQUIREMENTS
To install and repair Webasto heating and cooling systems you need to
have completed a special company training course and have the appro- 1.7.1. A clearly visible tell-tale in the operator's field of view shall inform when
priate technical documentation, special tools and special equipment. the combustion heater is switched on or off.
Installation and repair may ONLY be carried out by persons trained and 2. VEHICLE INSTALLATION REQUIREMENTS
certified in a Webasto training course. NEVER try to install or repair We-
basto heating or cooling systems if you have not completed a Webasto 2.1. Scope
training course, you do not have the necessary technical skills and you
do not have the technical documentation, tools and equipment available 2.1.1. Subject to paragraph 2.1.2. combustion heaters shall be installed ac-
to ensure that you can complete the installation and repair work properly. cording to the requirements of this Annex.

Only use genuine Webasto parts. See the Webasto air and water heat- 2.1.2. Vehicles of category O having liquid fuel heaters are deemed to comply
ers accessories catalogue for this purpose. with the requirements of this Annex.

1.2 Operation 2.2. Positioning of heater

To ensure safe operation, we recommend having the heater checked every two 2.2.1. Body sections and any other components in the vicinity of the heater
years by an authorised Webasto dealer, especially when used over a long period must be protected from excessive heat and the possibility of fuel or oil
and/or under extreme environmental conditions. contamination.

Do not operate the heater in closed rooms due to the danger of poisoning and suf- 2.2.2. The combustion heater shall not constitute a risk of fire, even in the case
focation. of overheating. This requirement shall be deemed to be fulfilled if the in-
stallation ensures an adequate distance to all parts and suitable ventila-
Always switch off the heater before refuelling. tion, by the use of fire resistant materials or by the use of heat shields.
The heater may only be used with the prescribed fuel Diesel (DIN EN 590) or pet- 2.2.3. In the case of M2 and M3 vehicles, the heater must not be positioned in
rol (DIN EN 227). the passenger compartment. However, an installation in an effectively
sealed envelope which also complies with the conditions in paragraph
The heater may not be cleaned with a high-pressure cleaner. 2.2.2 may be used.
1.3 Please note 2.2.4. The label referred to in paragraph 1.4 or a duplicate, must be positioned
so that it can be easily read when the heater is installed in the vehicle.
ALWAYS follow all Webasto installation and operating instructions and observe all
warnings. 2.2.5. Every reasonable precaution should be taken in positioning the heater
to minimise the risk of injury and damage to personal property.
To become familiar with and understand all functions and properties of the heater,
the operating instructions must be read carefully and observed at all times. 2.3. Fuel supply
For proper, safe installation and repair work, the installation instructions with all 2.3.1. The fuel filler must not be situated in the passenger compartment and
warnings and safety information must be carefully read and observed at all times. must be provided with an effective cap to prevent fuel spillage.
Please always contact a workshop authorised by Webasto for all installation and
repair work. 2.3.2. In the case of liquid fuel heaters, where a supply separate to that of the
vehicle is provided, the type of fuel and its filler point must be clearly la-
Important belled.
Webasto shall assume no liability for defects, damage and injuries resulting 2.3.3. A notice, indicating that the heater must be shut down before refuelling,
from a failure to observe the installation, repair and operating instructions must be affixed to the fuelling point. In addition a suitable instruction
of the information contained in them. must be included in the manufacturer's operating manual.
This liability exclusion particularly applies to improper installations and re- 2.4. Exhaust system
pairs, installations and repairs by untrained persons or in the case of a fail-
ure to use genuine spare parts. 2.4.1. The exhaust outlet must be located so as to prevent emissions from en-
tering the vehicle through ventilators, heated air inlets or opening win-
The liability due to culpable disregard to life, limb or health and due to dam- dows.
age or injuries caused by a wilful or reckless breach of duty remain unaf-
fected, as does the obligatory product liability. 2.5. Combustion air inlet
Installation should be carried out according to the general, standard rules 2.5.1. The air for the combustion chamber of the heater must not be drawn
of technology. Unless specified otherwise, fasten hoses, lines and wiring from the passenger compartment of the vehicle.
harnesses to original vehicle lines and wiring harnesses using cable ties.
Insulate loose wire ends and tie back. 2.5.2. The air inlet must be so positioned or guarded that blocking by rubbish
or luggage is unlikely.
Sharp edges should be fitted with rub protection (split-open fuel hose)!
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax 2.6. Heating air inlet
(Tectyl 100K, Order No. 111329).
2.6.1. The heating air supply may be fresh or recirculated air and must be
Observe the instructions and guidelines of the respective vehicle manufac- drawn from a clean area not likely to be contaminated by exhaust fumes
turer for demounting and mounting vehicle specific components! emitted either by the propulsion engine, the combustion heater or any
other vehicle source.
The initial startup is to be executed with the Webasto Thermo Test Diagno-
sis. 2.6.2. The inlet duct must be protected by mesh or other suitable means.
When installing an IPCU, the corresponding settings must be checked or 2.7. Heating air outlet
adjusted before the installation.
2.7.1. Any ducting used to route the hot air through the vehicle must be so po-
2 Statutory regulations governing installation sitioned or protected that no injury or damage could be caused if it were
to be touched.
Guidelines Thermo Top Evo
2.7.2. The air outlet must be so positioned or guarded that blocking by rubbish
Heating Directive ECE R122 E1 00 0258 or luggage is unlikely.
EMC Directive ECE R10 E1 03 5627 End of excerpt.
Note In multilingual versions the German language is binding.
The regulations of these guidelines are binding in the scope of the Directive
70/156/EEC and/or 2007/46/EC (for new vehicle models from 29/04/2009) and
should also be observed in countries in which there are no special regulations.
Important
Failure to follow the installation instructions will result in the invalidation of the type
approval for the heater and therefore invalidation of the general homologation of
the vehicle.
Note
For vehicles with an EU permit, no entry in accordance with § 19 Sub-Section 4
of Annex VIII b to the Road Traffic Act is required.
2.1 Excerpt from the directive 2001/56/EC Appendix VII for the
installation of the heater

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Peugeot 3008 / 5008

Information on Validity
This installation documentation applies to Peugeot 3008 / 5008 1.6 Diesel vehicles - for validity, see page 1 - from
model year 2011 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 installa-
tion with respect to this installation documentation.
Vehicle and engine types, equipment variants and other specifications not listed in this installation documentation
have not been tested. However, installation according to this installation documentation may be possible.

Technical Information

Special tools
• Hose clamp pliers for self-clamping hose clamps
• Hose clamp pliers for Clic hose clamps of type W
• Automatic wire stripper 0.2 - 6mm²
• Crimping pliers for cable lug / tab connector 0.5 - 6mm²
• Torque wrench for 2.0 - 10 Nm
• Hose clamping pliers
• Metric thread-setter kit
• Webasto Thermo Test Diagnosis with current software
Dimensions
• All dimensions are in mm.
Tightening torque values
• Tightening torque values of 5x13 heater bolts and 5x11 heater stud bolts = 8Nm.
• Tightening torque values of 5x15 retaining plate of water connection piece bolts = 7Nm.
• Tighten other bolt connections in accordance with manufacturer's instructions or in accordance with state-of-the-
art-technology.

Explanatory Notes on Document

You will find an identification mark on the outside Special features are highlighted using the following symbols:
top right corner of the page in question to provide
you with a quick overview of the individual working
steps.

Mechanical system Specific risk of injury or

fatal accidents

Electrical system Specific risk of damage to

components

Coolant circuit Specific risk of fire and explosion

Combustion air Reference to general installation instructions

of the Webasto components or to the
manufacturer's vehicle-specific documents
Reference to a special technical feature
Fuel

The arrow in the vehicle icon

indicates the position on the vehicle
Exhaust gas and the viewing angle

Software

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Peugeot 3008 / 5008

Preliminary Work
Vehicle

• Open the fuel tank cap.

• Ventilate the fuel tank.
• Close the fuel tank cap again.
• Depressurise the cooling system.
• Disconnect the battery and remove it fully along with the carrier.
• Remove the underride protection (if available).
• Remove the right front wheel.
• Remove the front right and left wheel well trim.
• Remove the bumper trim.
• Remove the right headlight.
• Remove the washer reservoir.
• Remove the air cleaner housing.
• Detach the exhaust pipe from the DPF and take it out of the brackets.
• Use the cable grommet in the right wheel well (passenger compartment pass through).
• Remove the lower instrument panel on the driver's side, expose the BSI.
• Remove the cover of the upper footwell trim on the driver's and front passenger's side.
• Remove the lateral trim of the instrument panel on the driver's side (only for Telestart T100 HTM).

Execute the following jobs only when they are required by the process:

• Remove the right rear wheel.

• Remove the right rear wheel well trim.
• Detach the lateral trims on the fuel tank.
• Detach the screw fitting of the filler neck on the fuel tank.
• Lower the fuel tank and support it with suitable means.

Heater

• Remove years that do not apply from the type and duplicate label.
• Attach the duplicate label (type label) in the appropriate place in the engine compartment.

1 Heater Installation Location

Figure shows Peugeot 3008.

1 Heater
Installation
location

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Peugeot 3008 / 5008

1 2 3 2 Preparing Wiring Harnesses

Produce connections as shown in wiring dia-
gram. Wire sections retain their numbering in
the entire document.
Insulate brown (br) wire 1 from wiring harness Preparing
1 of passenger compartment 1 and tie back. wiring har-
ness
2 Connect red/black (rt/sw) wire with red
4 (rt) wire (soldering connector)
2 Red/black (rt/sw) wire of heater control X10
3 Red (rt) wire for fuse F2
4 Green/white (gn/ws) wire of heater X1/5
5 Additional green/white (gn/ws) wire
5 2 3000mm long

1 Slide 17 mm dia., 1650 mm long corrugated

tube 2 (slit longitudinally) on wiring harnesses
of heater, passenger compartment, heater
control and metering pump. Replace fuse 1
F2 30A with fuse 1A.
Preparing
wiring har-
ness

1 Slide 10mm dia., 1500 mm long corrugated

tube 1 on wiring harness of heater control and
green/white (gn/ws) wire 5 .

5
Preparing
wiring har-
ness

9 Produce connections as shown in wiring dia-

gram. Pull out connector from wiring harness
2 of heater control 2. Disconnect coupling from
wiring harness extension 1. Insert additional
green/white (gn/ws) wire 5 also into wiring
harness extension 1. Connect-
2 5 ing wires
2 Red/black (rt/sw) wire of heater control
10 wiring harness
6 Red (rt) wire of wiring harness extension X10
7 7 Violet (vi) wire of wiring harness extension X10
8 Brown (br) wire of wiring harness extension X10
9 Yellow (ge) wire of heater control wiring harness
10 Brown (br) wire of heater control wiring
8 6 1 5 harness

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Peugeot 3008 / 5008

Produce connections as shown in wiring dia-

gram.

Cutting
11 12 13
br wires to
0,5² length
50 100 350

Connect wires to relay socket according to

wiring diagram. K1 relay is inserted only after
13 installing the relay socket.

86 30
Preparing
K1
K1 relay
85 87 87a

12

11

1 12 2 1 5 mm dia. cable lug

2 Relay socket K1
11 50 mm long brown (br) wire
11 12 100 mm long brown (br) wire
13 350 mm long brown (br) wire
Crimping
cable lug

13

1 2 3 4 Complete connector of metering pump after

routing. Pin assignment is not relevant.

1 Connector housing
2 Lock
3 Blue/brown (bl / br) wires Disman-
4 Coding tling con-
5 5 Timer lock nector
5

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Peugeot 3008 / 5008

Electrical System
Positive wire Wiring harness pass through
1 Positive wire on positive distributor of battery For wiring harness routing, please see following page.
1 Use existing protective rubber plug for wiring har-
ness pass through of passenger compartment.

1 8 9

Wiring har-
ness rout-
ing
Do not install the metering pump diagram
wiring harness until later togeth-
er with fuel line along the original
vehicle fuel lines on the under-
body

1 10 2 11

Earth wire Fuse holder of engine compartment

1 Earth wire on original vehicle earth support 1 5.5 mm dia. hole; M5x20 bolt, washer, re-
point taining plate of fuse holder, washer, flanged
nut
2 Fuses F1-2

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Peugeot 3008 / 5008

Wiring Harness Routing

1 Wiring harnesses in 17 mm dia. corrugat-
ed tube
1
Routing
wiring har-
nesses

1 12
Peugeot 3008

Install retaining clamp 1 [2x] and fasten wiring

harness with cable tie.
1
2 Wiring harnesses in 17 mm dia. corrugat- Routing
ed tube wiring har-
nesses

1 2 1 13

1 1 5x13 self-tapping screw, existing hole

2 25 mm dia. rubber-coated p-clamp
3 Wiring harnesses in 17 mm dia. corrugat-
ed tube

Routing
wiring har-
nesses

3 2 14

2 Peugeot 5008

Install retaining clamp 1 [2x] and fasten wiring

harness with cable tie.
1
2 Wiring harnesses in 17 mm dia. corrugat- Routing
ed tube wiring har-
nesses

1 1 15

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Peugeot 3008 / 5008

2 Install retaining clamp 1 [2x] and fasten wiring

harness with cable tie.

2 Wiring harnesses in 17 mm dia. corrugat-

1 ed tube
Routing
wiring har-
nesses

1 1 16

1 Washer reservoir will be installed later.

1 Wiring harness of heater control and

green/white (gn/ws) wire in 10 mm dia.
corrugated tube
Routing
wiring har-
nesses
1

17

1 Route wiring harness 3 through existing pro-

tective rubber plug 1 to the passenger com-
partment.

2 Original vehicle wiring harness pass

1 through of engine compartment Routing
3 Wiring harness of heater control and wiring har-
green/white (gn/ws) wire in 10 mm dia. nesses
2 corrugated tube

3 18

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Peugeot 3008 / 5008

Fan Controller

Webasto Peugeot
30
15
Wiring dia-
HG gram
X2 1 2 2 5 X1
F2 F1

rt
4²
3
4

gn/ws
0,75²
1
rt/sw ge gn/ws
0,5² 0,5²
0,75²
br br
0,5² 0,5²
! 5
9 2 10 br
gn/ws 13
0,75² 0,5²

br rt vi 86 30 St A 6
0,5² 0,5² 0,5²
K1
8 6 7 BSI
85 87 87a

br
12
X10 0,5²
br
11 0,5²

31

Webasto components Vehicle components Colours and symbols

HG Heater TT-Evo St A 40-pin connector BSI rt red
X1 6-pin heater connector BSI Central switching unit sw black
X2 2-pin heater connector ge yellow
X10 4-pin connector gn green
Heater control Legend
ws white
F2 Replace fuse 30A with br brown
1A
F1 20A fuse Insulate wire ends and
K1 Changeover relay tie back
Wiring colours may vary.

5 5.5 mm dia. hole at position 2. Watch compo-

nents behind. Insert additional green/white
(gn/ws) wire 5 in relay socket K1/86. Make
connection as shown in wiring diagram.

1 K1 relay socket Mounting

12
2 M5x16 bolt, flanged nut K1 relay
12 Brown (br) wire of K1/85, cable lug socket and
earth wire

2 1 19

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Peugeot 3008 / 5008

1 Align K1 relay socket

2 Mount K1 relay

Mounting
K1 relay

2 1 20

1 View of BSI.

1 Socket for 2-piece connector. 40-pin

1

Detaching
BSI and
routing
downward

21

1 Press in locking lug 1 and fold down bar 3.

2 20-pin blue connector

Pulling
connector
3 off BSI and
removing it

2 22
Connection to 20-pin blue (bl) connector 1
from BSI. Crimp microtimer on brown (br)
wire 13 and insert in PIN 6. Complete BSI
connector and mount.

13 13 Brown (br) wire of K1/30 Connec-

tion of BSI

1 23

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Peugeot 3008 / 5008

Digital Timer
1 Digital timer

Mounting
digital tim-
er

3 24

1 Remote Option (Telestart)

Bend bracket of receiver 3 as shown.

1 M5x20 bolt, washer, flanged nut, existing

hole Mounting
2 2 Receiver mounted receiver

3 25

1 1 Antenna

Mounting
antenna

26
Temperature sensor T100 HTM

Fasten temperature sensor 1 with adhesive

tape.

Installing
tempera-
ture sensor

1 27

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Peugeot 3008 / 5008

1 Preparing Heater
1 Water connection piece, sealing ring [2x
each]
2 5x15 self-tapping bolt, retaining plate of
water connection piece Mounting
water con-
2 nection
piece

1 28

1 2 2 1 Bracket
2 5x13 self-tapping bolt [3x]
3 Holes for mounting heater [3x]
3

Mounting
3
bracket

2 3 29

1 2 Preparing Installation Location

Cut out template 3 and apply at the markings.

1 50mm edge protection

2 Copy hole pattern [3x] Copying
3 hole pat-
2 tern

2 30

1 1 7 mm dia. hole [2x]

2 Drill 9.1 mm dia. hole; rivet nut

2 Installing
rivet nut

1 31

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Peugeot 3008 / 5008

1 2 Installing Heater
1 Bracket of heater
2 M6x20 bolt, flanged nut

Mounting
heater

32
1 M6x20 bolt, large diameter washer,
flanged nut

Mounting
heater

1 33

1 1 M6x20 bolt, spring lockwasher

Mounting
heater

34
All models

1 Fasten wiring harness with cable ties.

2 Wiring harnesses in 17 mm dia. corrugat-

ed tube Routing
wiring har-
2 nesses

35

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Peugeot 3008 / 5008

1 Wiring harness of heater [2x]

2 Clip-type cable tie in existing hole
3 Wiring harness of heater control and
green/white (gn/ws) wire in 10 mm dia.
corrugated tube
Routing/at-
taching wir-
3 ing
harnesses

2 36

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Peugeot 3008 / 5008

Fuel
CAUTION!
Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.

Catch any fuel running off in 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 as shown in the wiring harness rout-
ing diagram.

1 Route fuel line and wiring harness of meter-

ing pump in 10 mm dia., 1200 mm long corru-
gated tube 1 to firewall.

2 90° moulded hose, 10 mm dia. clamp [2x]

Connect-
ing heater

2 37

1 Washer reservoir will be installed later. Route

fuel line and wiring harness of metering pump
in 10 mm dia. corrugated tube 1 to original ve-
hicle pass through of underbody.

Routing
lines
1

38

1 1 Fuel line and wiring harness of metering

pump in 10 mm dia. corrugated tube
2 Original vehicle wiring harness pass
through of underbody

Routing
lines

2 39

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Peugeot 3008 / 5008

Guide wiring harness of metering pump and

fuel line out of original vehicle line duct (exist-
ing pass through 1) and slide on 10 mm dia.,
500 mm long corrugated tube 2.

2 Routing
lines

1 40

1 Version A

Lower and support fuel tank according to

manufacturer's instructions. Remove fuel-
tank sending unit 1 in accordance with manu-
facturer's instructions. Insert washer outer Fuel ex-
dia. = 18 mm 3 into recess. traction
2
2 Copy hole pattern, 6 mm dia. hole

3 41

1 Shape fuel standpipe 1 according to tem-

plate, cut to length, install and align.

Installing
fuel stand-
pipe

42
1 Flanged nut
2 Fuel standpipe

2 Mounting
fuel stand-
pipe

43

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Peugeot 3008 / 5008

1 Version B

Lower and support fuel tank according to

manufacturer's instructions. Remove fuel-
tank sending unit 1 in accordance with manu-
facturer's instructions. Place washer outer Fuel ex-
dia. = 18mm 3 as shown. traction
2 Copy hole pattern, 6 mm dia. hole
2

3 44

1 Shape fuel standpipe 1 according to tem-

plate, cut to length, install and align.

Installing
fuel stand-
1 pipe

45

1 2 All models

Install fuel-tank sending unit 3 in accordance

with manufacturer's instructions and re-install
3 the fuel tank.
Connect-
1 Fuel standpipe ing fuel line
2 Hose section, 10 mm dia. clamp [2x]
3 Fuel line

46

1 2 1 Perforated bracket
2 M6x25 bolt, flanged nut
3 Support angle
4 Mounting
5 Metering pump
Premount-
ing meter-
3 ing pump

5 4 47

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Peugeot 3008 / 5008

1 1 Pin lock
2 Original vehicle stud bolt
3 Metering pump

Mounting
metering
pump
2

3 48

1 2 3 Slide 10 mm dia., 330mm long corrugated

tube 1 onto fuel line of fuel standpipe.

2 Wiring harness of metering pump, con-

nector mounted
3 180° moulded hose, 10 mm dia. clamp, Connect-
fuel line ing meter-
4 Hose section, 10 mm dia. clamp, fuel line ing pump
5 10 mm dia. corrugated tube
5

4 49
1 Original vehicle stud bolt
2 Original vehicle flanged nut
3 Underbody trim

Mounting
underbody
1 trim

3 2 50

1 Combustion Air
Discard section X.

1 Combustion air pipe

a = 620 Cutting
combus-
tion air pipe
to length

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Peugeot 3008 / 5008

1 Reinstall washer reservoir 3.

1 Combustion air pipe

3 2 Cable tie [3x]

Mounting
2
combus-
tion air pipe
2

2 51

1 2 1 Combustion air pipe

2 M5x16 bolt, flanged nut
3 Silencer
4 Original vehicle bolt
5 Perforated bracket
6 6 51 mm dia. p-clamp Mounting
silencer
5

3 52

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Peugeot 3008 / 5008

1 2 Exhaust Gas
Discard section X.

1 Exhaust pipe
a = 395 Preparing
2 Exhaust end section exhaust
b = 95 pipe

a b

X
1 Perforated bracket
95

Angling
down per-
82
forated
bracket

90°

1 1 Silencer
2 Perforated bracket
3 M6x16 bolt, spring lockwasher

Premount-
ing silencer

3 2 53

1 Align silencer 3 vertically.

1 Exhaust pipe
2 Hose clamp
2 4 Perforated bracket
5 M6x20 bolt, large diameter washer, Mounting
5 flanged nut, existing hole silencer
3

4 54

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Peugeot 3008 / 5008

1 2 3 Slide exhaust-gas insulation 1 on to exhaust

pipe 5.

2 M6x20 bolt, p-clamp, flanged nut

3 Angle bracket
4 Original vehicle bolt Mounting
exhaust
4 pipe

5 55

1 1 Hose clamp
2 Exhaust pipe

Mounting
exhaust
pipe

2 56

1 2 1 Hose clamp
2 M6x20 bolt, p-clamp, flanged nut
3 Angle bracket
4 Original vehicle bolt, large diameter
washer
5 Exhaust end section Mounting
end section
3

5 4 57

1 1 Ensure sufficient distance of exhaust silencer

at position 1 from neighbouring components,
correct if necessary.

Aligning si-
lencer and
end section

58

Ident. No.: 1318133B_EN Status: 08.01.2013 © Webasto Thermo & Comfort SE 23

Peugeot 3008 / 5008

1 2 Preparing Wiring Harness of Circu-

lating Pump
Dismantle connector of circulating pump.
Connector of circulating pump is completed
1 3 again after sliding 6 mm dia. corrugated tube. Disman-
tling con-
1 Connector nector
2 Timer lock [2x]
3 Lock
4 Brown (br) wire
5 Black (sw) wire

5 4 2 59
Slide on 6 mm dia., 1150 mm long corrugated
tube on wiring harness of circulating pump.
Route excess wiring harness into corrugated
tube.
2
1 Connector of circulating pump completed Pushing on
corrugated
2 tube

1 60

Ident. No.: 1318133B_EN Status: 08.01.2013 © Webasto Thermo & Comfort SE 24

Peugeot 3008 / 5008

Coolant Circuit
WARNING!
Any coolant running off should be collected in an appropriate container. Install hoses so that they are
kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hos-
es cannot be damaged. The heater must be filled with coolant when installing the hoses.
The connection should be "inline" based on the following diagram:

Hose rout-
ing dia-
gram

E C
F
D

H
G

All spring clips without a specific designation = 25 mm dia.

All connecting pipes and = 18x18 mm dia.
1 = Black (sw) rubber isolator

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Peugeot 3008 / 5008

Discard section X.
Hose A =180°, 18 mm dia. moulded hose
B C X
B = 620
C = 1340
D = 60 Cutting
E X
E = 60 hoses to
D F G H
F = 60 length
G = 60
H = 1900

1 1 1 1 Push braided protection hoses onto hose B,

C and H and cut to length.
B Cut heat shrink plastic tubing to length.

1 50 mm long heat shrink plastic tubing [6x]

C 2 100 mm long heat shrink plastic tubing Preparing
hoses

2
H

1 1
1 Copy hole pattern 1 for 7.0 mm dia. hole and
drill hole.

Preparing
hose rout-
130 10 ing

61

1 Copy hole pattern 1 for 7.0 mm dia. hole and

drill hole.

Preparing
hose rout-
10 ing

62

Ident. No.: 1318133B_EN Status: 08.01.2013 © Webasto Thermo & Comfort SE 26

Peugeot 3008 / 5008

1 Copy hole pattern 1 for 7.0 mm dia. hole and

drill hole.

Preparing
10 hose rout-
130 ing

63
Copy hole pattern 1 for 9.1 mm dia. hole, drill
hole and install M6 rivet nut.

Preparing
35
mounting
of circulat-
35 ing pump

1 64

1 1 Circulating pump
2 Mounting circulating pump
3 M6x25 bolt

Mounting
circulating
pump
3
2

65
1 Remove retaining clip and discard.
2 Original vehicle wire

Removing
retaining
2 clip

1 66

Ident. No.: 1318133B_EN Status: 08.01.2013 © Webasto Thermo & Comfort SE 27

Peugeot 3008 / 5008

1 2 3 Cut off hose on engine outlet at marking.

1 Hose coupling of engine outlet

2 Engine outlet hose section
3 Hose section of heat exchanger inlet
Cutting
point

60

67

1 A 1 Engine outlet hose section

Mounting
hose A

68

Connect-
A ing and
routing
hose B

B 69

B 1 C 1 Circulating pump

Connect-
ing circu-
lating
pump

70

Ident. No.: 1318133B_EN Status: 08.01.2013 © Webasto Thermo & Comfort SE 28

Peugeot 3008 / 5008

E C Align hoses. Ensure sufficient distance from

neighbouring components.

Connect-
ing heater

D 71

H Align hoses. Ensure sufficient distance from

neighbouring components.

Connect-
ing heater

G 72

Hose rout-
ing

H 73

H 1 2 1 Rubber isolator
2 Hose section of heat exchanger inlet
3 Cable tie

Connec-
tion of heat
exchanger
inlet

3 74

Ident. No.: 1318133B_EN Status: 08.01.2013 © Webasto Thermo & Comfort SE 29

Peugeot 3008 / 5008

1 B Align hoses. Ensure sufficient distance from

neighbouring components.

1 Hose bracket
2 Hose bracket
Hose rout-
ing

H 2 75

1 1 Wiring harness of circulating pump

Mounting
wiring har-
ness

76

1 1 Wiring harness of circulating pump

2 Circulating pump

Mounting
wiring har-
ness

2 77

G 1 2 Align hoses. Ensure sufficient distance from

neighbouring components.

1 Clip-type cable tie, existing hole

2 Wiring harness of heater in 10 mm dia.
corrugated tube Hose rout-
ing
H

78

Ident. No.: 1318133B_EN Status: 08.01.2013 © Webasto Thermo & Comfort SE 30

Peugeot 3008 / 5008

1 1 M6x20 bolt, original vehicle hole, flanged

nut, 48mm dia. rubber-coated p-clamp
2 Wiring harness of circulating pump in
6mm dia. corrugated tube
3 Cable tie
C
Hose rout-
ing
H

3 2 79

1 2 3 H 1 3 1 M6x20 bolt, flanged nut, 48mm dia. rub-

ber-coated p-clamp
2 Wiring harness of circulating pump in
6mm dia. corrugated tube
3 Cable tie [2x]
Hose rout-
ing

80

1 2 3 H 1 M6x20 bolt, flanged nut, 48mm dia. rub-

ber-coated p-clamp
3 2 Wiring harness of circulating pump in
6mm dia. corrugated tube
3 Cable tie [2x]
Hose rout-
ing

81

Ident. No.: 1318133B_EN Status: 08.01.2013 © Webasto Thermo & Comfort SE 31

Peugeot 3008 / 5008

Final Work
WARNING!
Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm
seating. Insulate all loose wires and tie back.
Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax
(Tectyl 100K, Order No. 111329).

Encode BSI according to manufacturer's instructions with diag. box or PP2000 on parking heater.

Note:
To check fan function, disconnect battery for 20 seconds. Wait 30 seconds after connecting the
battery and activate the "Vent" function of the heater control.
Requirement: Battery capacity >80%.

• Connect the battery.

• Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications.
• Adjust digital timer, teach Telestart transmitter.
• Settings on the A/C control panel are not required.
• Place the "Switch off parking heater before refuelling" signboard near the filler neck.
• For the initial start-up and function check, see installation instructions.

1 2 1 Underride protection
2 Exhaust end section
3 Cutout in underride protection

Mounting
underride
protection

3 82

Webasto Thermo & Comfort SE

Postfach 1410
82199 Gilching
Germany
Internet: www.webasto.com
Technical Extranet:
http://dealers.webasto.com

Ident. No.: 1318133B_EN Status: 08.01.2013 © Webasto Thermo & Comfort SE 32

 Peugeot 3008 / 5008

Template of Bracket Hole Pattern

9,1

7,0

100mm

7,0

Scale 1:1

Compare the size of the printed version with dimension

lines.
Permitted tolerance a maximum of 2%.

Set the printer settings to “no margin” or “minimise mar- 100mm

gins” and 100% of the normal size.

0
Ident. No.: 1318133B_EN Status: 08.01.2013 © Webasto Thermo & Comfort SE 33
Peugeot 3008 / 5008

Template for Fuel Standpipe

Topview

100mm

Scale 1:1

Compare the size of the printed version with dimension

lines.
Permitted tolerance a maximum of 2%.

Set the printer settings to “no margin” or “minimise mar-

gins” and 100% of the normal size. 100mm

Ident. No.: 1318133B_EN Status: 08.01.2013 © Webasto Thermo & Comfort SE 34

Peugeot 3008 / 5008

Operating Instructions for Automatic Air-Conditioning

Please remove this page in case of automatic air-conditioning and add it 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.

Passenger compartment monitoring, if installed, must be deactivated in addition to the vehicle settings
for the heating operation.
For information on deactivation, please see the vehicle owner's manual.

No other settings are required on the A/C control panel.

1 2 1 1A main fuse F2 of passenger compart-

ment
2 20A heater fuse F1

Fuses of
engine
compart-
ment

83