K

Cold Start Kit

E1
Thermo Top Evo Parking Heater 00 0258

Installation Documentation

PSA
2008 / Partner / Berlingo
Validity
Manufacturer Model Type Model year EG BE No. / ABE
Peugeot 2008 C From model year 2015 e2 * 2007 / 46 * 0070 * ...
Peugeot Partner 7 From model year 2014 e2 * 2001 / 116 * 0365 * ...
Citroen Berlingo 7 From model year 2012 e2 * 2001 / 116 * 0366 * ...

Motorisation Fuel Emission Transmission Output in kW Displacement in Engine code

standard type cm³
1.6 D Diesel Euro 6 SG 73 1560 BH02
1.6 D Diesel Euro 6 SG 88 1560 BH01

SG = manual transmission

Left-hand drive vehicle

Total installation time: approx. 1.5 hours

(Applies only to the retroffing of a cold start system in vehicles with an already retrofitted
parking heater).

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PSA 2008 / Partner / Berlingo

Table of Contents
Validity 1 Electrical System 6
Necessary Components 2 Preparing Electrical System 7
Information on Validity 2 System Wiring Diagram 2008 9
Information on Total Installation Time 2 Cold Start System Installation for Peugeot 2008 10
Installation Overview 3 System Wiring Diagram for Partner / Berlingo 14
Information on Operating and Installation Instructions 4 Cold Start System Installation for Partner / Berlingo 15
Information on Validity 5 Engine Control Unit Connection for All Vehicles 18
Technical Information 5 Final Work 19
Explanatory Notes on Document 5
Preliminary Work 6

Necessary Components
Description Order No.:
Additional cold start kit for PSA / Toyota TT-Evo 1325507_
Installation documentation for PSA 2008 / Partner / Berlingo 73/ 88kW diesel 1325764_

Information on Validity
This installation documentation applies only in combination with:

Description Order No.:

SET Peugeot 2008 petrol 81/ 96kW and diesel 73/ 88kW MY 2015 1325550_
(Set contains installation kit and cold start kit)
Installation documentation for Peugeot 2008 petrol and diesel MY 2015 1324528_
or

Description Order No.:

SET PSA Berlingo / Partner 73/ 88kW diesel TT-Evo MY 2015 1325777_
(Set contains installation kit, fuel additional kit and cold start kit)
Installation documentation for PSA Berlingo / Partner diesel MY 2012 1318865_

Information on Total Installation Time

The total installation time includes the time needed for mounting and demounting the vehicle-specific components, the heat-
er 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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PSA 2008 / Partner / Berlingo

Installation Overview

Legend:
1. CLR module Peugeot 2008
2. Temperature sensor (RTD)
3. Adapter connector

2
1

Peugeot Partner
Citroen Berlingo

2
1

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PSA 2008 / Partner / Berlingo

Information on Operating and Installation Instructions

1 Important information (not complete) 2.1 Excerpt from ECE regulation 122 (heating system) paragraph
5 for the installation of the heater
1.1 Installation and repair
Beginning of excerpt.
The improper installation or repair of Webasto heating and cooling systems
can cause fire or the leakage of deadly carbon monoxide, leading to serious ANNEX VII
injury or death.
REQUIREMENTS FOR COMBUSTION HEATERS
To install and repair Webasto heating and cooling systems you need to have AND THEIR INSTALLATION
completed a special company training course and have the appropriate tech-
nical documentation, special tools and special equipment. 1. GENERAL REQUIREMENTS
Installation and repair may ONLY be carried out by persons trained and cer- 1.7.1. A clearly visible tell-tale in the operator's field of view shall inform when the
tified in a Webasto training course. NEVER try to install or repair Webasto combustion heater is switched on or off.
heating or cooling systems if you have not completed a Webasto training
course, you do not have the necessary technical skills and you do not have 2. VEHICLE INSTALLATION REQUIREMENTS
the technical documentation, tools and equipment available to ensure that
you can complete the installation and repair work properly. 2.1. Scope
Only use genuine Webasto parts. See the Webasto air and water heaters ac- 2.1.1. Subject to paragraph 2.1.2. combustion heaters shall be installed according
cessories catalogue for this purpose. to the requirements of this Annex.
1.2 Operation 2.1.2. Vehicles of category O having liquid fuel heaters are deemed to comply with
the requirements of this Annex.
To ensure safe operation, we recommend having the heater checked every two years
by an authorised Webasto dealer, especially when used over a long period and/or un- 2.2. Positioning of heater
der extreme environmental conditions.
2.2.1. Body sections and any other components in the vicinity of the heater must be
Do not operate the heater in closed rooms due to the danger of poisoning and suffo- protected from excessive heat and the possibility of fuel or oil contamination.
cation.
2.2.2. The combustion heater shall not constitute a risk of fire, even in the case of
Always switch off the heater before refuelling. overheating. This requirement shall be deemed to be fulfilled if the installation
ensures an adequate distance to all parts and suitable ventilation, by the use
The heater may only be used with the prescribed fuel diesel (DIN EN 590) or petrol of fire resistant materials or by the use of heat shields.
(DIN EN 228).
2.2.3. In the case of M2 and M3 vehicles, the heater must not be positioned in the
The heater may not be cleaned with a high-pressure cleaner. passenger compartment. However, an installation in an effectively sealed en-
velope which also complies with the conditions in paragraph 2.2.2 may be
1.3 Please note used.
ALWAYS follow all Webasto installation and operating instructions and observe all 2.2.4. The label referred to in paragraph 1.4 or a duplicate, must be positioned so
warnings. that it can be easily read when the heater is installed in the vehicle.
To become familiar with and understand all functions and properties of the heater, the 2.2.5. Every reasonable precaution should be taken in positioning the heater to
operating instructions must be read carefully and observed at all times. minimise the risk of injury and damage to personal property.
For proper, safe installation and repair work, the installation instructions with all warn-
ings and safety information must be carefully read and observed at all times. Please 2.3. Fuel supply
always contact a workshop authorised by Webasto for all installation and repair work. 2.3.1. The fuel filler must not be situated in the passenger compartment and must
be provided with an effective cap to prevent fuel spillage.
Important
2.3.2. In the case of liquid fuel heaters, where a supply separate to that of the vehi-
Webasto shall assume no liability for defects, damage and injuries resulting cle is provided, the type of fuel and its filler point must be clearly labelled.
from a failure to observe the installation, repair and operating instructions of the
information contained in them. 2.3.3. A notice, indicating that the heater must be shut down before refuelling, must
be affixed to the fuelling point. In addition a suitable instruction must be in-
This liability exclusion particularly applies to improper installations and repairs, cluded in the manufacturer's operating manual.
installations and repairs by untrained persons or in the case of a failure to use
genuine spare parts. 2.4. Exhaust system
The liability due to culpable disregard to life, limb or health and due to damage 2.4.1. The exhaust outlet must be located so as to prevent emissions from entering
or injuries caused by a wilful or reckless breach of duty remain unaffected, as the vehicle through ventilators, heated air inlets or opening windows.
does the obligatory product liability.
2.5. Combustion air inlet
Installation should be carried out according to the general, standard rules of
technology. Unless specified otherwise, fasten hoses, lines and wiring harness- 2.5.1. The air for the combustion chamber of the heater must not be drawn from the
es to original vehicle lines and wiring harnesses using cable ties. Insulate loose passenger compartment of the vehicle.
wire ends and tie back. Connectors on electronic components must audibly
snap into place during assembly. 2.5.2. The air inlet must be so positioned or guarded that blocking by rubbish or lug-
gage is unlikely.
Sharp edges should be fitted with rub protection. Spray unfinished body areas,
e.g. drilled holes, with anti-corrosion wax 2.6. Heating air inlet
(Tectyl 100K).
2.6.1. The heating air supply may be fresh or recirculated air and must be drawn
Observe the instructions and guidelines of the respective vehicle manufacturer from a clean area not likely to be contaminated by exhaust fumes emitted ei-
for demounting and mounting vehicle specific components! ther by the propulsion engine, the combustion heater or any other vehicle
source.
The initial start-up is to be executed with the Webasto Thermo Test Diagnosis.
2.6.2. The inlet duct must be protected by mesh or other suitable means.
When installing a programmable control module (e.g. a PWM Gateway), the cor-
responding settings must be checked or adjusted. 2.7. Heating air outlet
2 Statutory regulations governing installation 2.7.1. Any ducting used to route the hot air through the vehicle must be so posi-
tioned or protected that no injury or damage could be caused if it were to be
Guidelines Thermo Top Evo touched.
Heating Directive ECE R122 E1 00 0258 2.7.2. The air outlet must be so positioned or guarded that blocking by rubbish or
EMC Directive ECE R10 E1 04 5627 luggage is unlikely.
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 ap-
proval for the heater and therefore invalidation of the general homologation of the
vehicle.
Note
The heater is licensed in accordance with paragraph 19, section 3, No. 2b of the StV-
ZO (German Road Traffic Licensing Authority).

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PSA 2008 / Partner / Berlingo

Information on Validity
This installation documentation applies to PSA 2008 / Partner / Berlingo 1.6 Diesel vehicles - for validity, see page 1 - from
model year 2012 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims ex-
cluded. Depending on the vehicle version and equipment, modifications may be necessary during installation 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
• Automatic wire stripper, 0.2 - 6mm²
• Crimping pliers for cable lug / tab connector, 0.5 - 6mm²
• Torque wrench for 2.0 - 10 Nm
• Webasto Thermo Test Diagnosis with current software

Dimensions
• All dimensions are in mm.

Tightening torque values

Tighten 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 top right corner of the page in question to provide you with a quick overview
of the individual working steps.

Mechanics Electrical System

Special features are highlighted using the following symbols:

Specific risk of damage to components. Reference to the manufacturer's vehicle-spe- F

cific documents.

Specific risk due to electrical voltage.

Reference to specific installation instructions of
Webasto components F
F
(demonstrated with the example of the FuelFix).

Specific risk of fire or explosion.

Reference to general installation instructions
of Webasto components.
Reference to a special technical feature.

!
Tightening torque according to the manu- Nm
facturer's vehicle-specific documents.
The arrow in the vehicle
icon indicates the
position on the vehicle
and the viewing angle.

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PSA 2008 / Partner / Berlingo

Preliminary Work

• Disconnect the battery.

• Remove the lateral instrument panel trim on the left side.
• Remove the lower instrument panel trim (central electrical box cover in passenger compart-
ment) on the driver's side.
• Remove the door sill trim on the driver's side (2008 only).
• Fold back the footwell trim (carpet) on the driver's side (2008 only).
• Remove the footwell trim on the driver's side (Partner / Berlingo only).
• Remove the cover of the fuse box in the engine compartment (Partner / Berlingo only).

Electrical System

2008

Wiring har-
ness routing
diagram for
passenger
compart-
ment

Partner /
Berlingo

Wiring har-
ness routing
diagram for
passenger
compart-
ment

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PSA 2008 / Partner / Berlingo

Preparing Electrical System

Wire sections retain their numbering in the
entire document.
Produce all following electrical connec-
tions as shown in the system wiring dia- Assigning
24
rt gram. wires
0,5²
sw
25 0,5²
24 Red (rt) wire of cold start wiring har-
ness
25 Black (sw) wire of cold start wiring
harness

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C 30 X

W
31 15
A
L H

Disconnect-
ing black (sw)
RTD wire from A /
assignment of
wires to be
CLR used

C 30 X
2.8 2.8
6.3

2.
1. 31 W 15
3. 6.3 6.3 6.3

L A H
6.3
2.8 2.8

rt/ws
21
0,75²
ws
26
0,5²

27
or
0,5²

RTD
Insulating
black (sw)
CLR wire / con-
necting wires
C 30 X
2.8 2.8
6.3

31 W 15 rt
6.3 6.3 6.3 24
0,5²

A sw
L 6.3
H 25
2.8 2.8 0,5²
sw
0,5² rt/ws
21
0,75²
ws
26
0,5²

27
or
0,5²
2

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System Wiring Diagram 2008

Webasto Peugeot 2008

30
rt
6² System wir-
HG ECM ing diagram
F2 F1 95 G
vi/ws
vi/ws

X10 OBD
6 14 1
A

B br
0,5²
F4 F3
RTD
K1 pk
0,5²

rt (gr) *
PWM 0,5²

GW A sw
CLR 0,5²
25 CAN H
W rt
0,5²
24 CAN L
15 L H
K2 ws 26
0,5²
or
0,5²
27 Y
rt/ws
0,75²
21
br
4² 15
31

Webasto components Vehicle components Colours and symbols

HG TT-Evo heater ECM Engine control unit rt red
F1 20A fuse G 120-pin connector of ECM sw black
F2 30A fuse OBD OBD socket outlet or orange
X10 4-pin socket of heater ws white
control Legend
br brown
A Connector of CLR gr grey
module wiring harness pk pink
B Socket of CLR module vi violet
wiring harness
F3 1A fuse Connection information
F4 25A fuse Y can be found in section
K1 Relay K1 ‘Fan Controller’ of the
PWM Pulse width modulator heater installation docu-
GW mentation.
K2 Additional relay X Cutting point
RTD Temperature sensor
CLR CLR module
* Wiring colours may vary.

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PSA 2008 / Partner / Berlingo

1 Cold Start System Installation

for Peugeot 2008
1 CLR module socket
2 M5x16 bolt, large diameter washer [2x],
nut Premount-
3 Angle bracket ing angle
4 Drill out hole to 8.5 mm dia. bracket
2

4 3

1 1 CLR module socket

2 CLR module

Installing
CLR mod-
ule
2

1 2 Route wiring harnesses 24 and 25 as

well as temperature sensor RTD in the
footwell.

1 Original vehicle bolt

2 CLR module socket Mounting
CLR module
socket

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RTD

Connecting
CLR sockets and
connectors
C X in passenger
2.8
30 2.8 compartment
6.3

31 W 15 rt
6.3 6.3 6.3 24
0,5²

A sw
L 6.3
H 25
2.8 2.8 0,5²

rt/ws
21
0,75²
ws
26
0,5²
or
27
0,5²

1 2 Detach OBD socket outlet from bracket.

1 Crimp butt connector [2x]

2 Wire (colour as per system wiring dia-
gram) of OBD socket outlet/ pin 6
6 3 Wire (colour as per system wiring dia- Connecting
ws gram) of OBD socket outlet/ pin 14 OBD socket
0,5² 14 26 White (ws) wire of CLR module/ H
26 1 outlet
cold start wiring harness
27 9 27 Orange (or) wire of CLR module/ L
or
0,5² cold start wiring harness

1 3 7

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PSA 2008 / Partner / Berlingo

Fold back carpet in footwell area.

1 Plug

Removing
plug

1 8

1 Route wiring harness 1 with temperature

sensor RTD through plug 2.

~100 Premounting
plug

RTD

2 9
Install temperature sensor RTD with plug
into opening 1.
Ensure proper tension relief!

Installing
temperature
sensor

1 10

1 2 Route wiring harness 1 with wires 24 and

25 in the engine compartment to the en-
gine control unit.

2 Wiring harness pass through

Routing
wires in the
engine com-
partment

11

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1 1 Engine control unit ECM

2 120-pin connector G

Detaching
2 engine con-
trol unit con-
nector

12

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PSA 2008 / Partner / Berlingo

System Wiring Diagram for Partner / Berlingo

Webasto Partner / Berlingo

30
rt
6²
System wir-
HG ECM
ing diagram
F2 F1 95 G
vi/ws
vi/ws

X10 OBD
6 14 1
A

B
br
0,5²

RTD
ge
0,5²

A sw
CLR 0,5²
25 CAN H
W rt
0,5²
24 CAN L
15 L H
ws 26
0,5²
or br
0,5²
27
1,0²
rt/ws
0,75²
21
br
1,0²
br 15
4²

31

Webasto components Vehicle components Colours and symbols

HG TT-Evo heater ECM Engine control unit rt red
F1 20A fuse G 120-pin connector of ECM sw black
F2 30A fuse OBD OBD socket outlet or orange
X10 4-pin socket of heater ws white
control Legend
br brown
A Connector of CLR vi violet
module wiring harness ge yellow
B Socket of CLR module
wiring harness
RTD Temperature sensor X Cutting point
CLR CLR module Wiring colours may vary.

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PSA 2008 / Partner / Berlingo

1 Cold Start System Installation

for Partner / Berlingo
1 Angle bracket
2 CLR module socket
3 M5x16 bolt, large diameter washer [2x], Premount-
2 nut ing angle
4 Drill out hole to 8.5 mm dia. bracket
4

3 13

1 Route wiring harnesses 24 and 25 as

well as temperature sensor RTD in the
footwell.
Route wiring harnesses 26 and 27 to
OBD socket outlet and adapter socket /
connector to the installation location of the Mounting
heater control. CLR module
socket
3 1 Original vehicle bolt
2 Install CLR module
3 CLR module socket

2 14

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PSA 2008 / Partner / Berlingo

RTD

Connecting
CLR sockets and
connectors
C X in passenger
2.8
30 2.8 compartment
6.3

31 W 15 rt
6.3 6.3 6.3 24
0,5²

A sw
L 6.3
H 25
2.8 2.8 0,5²

rt/ws
21
0,75²
ws
26
0,5²
or
27
0,5²

15

1 2 Detach OBD socket outlet from bracket.

1 Crimp butt connector [2x]

2 Wire (colour as per system wiring dia-
gram) of OBD socket outlet/ pin 6
6 3 Wire (colour as per system wiring dia- Connecting
ws gram) of OBD socket outlet/ pin 14 OBD socket
0,5² 14 26 White (ws) wire of CLR module/ H
26 1 outlet
cold start wiring harness
27 9 27 Orange (or) wire of CLR module/ L
or
0,5² cold start wiring harness

1 3 16

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PSA 2008 / Partner / Berlingo

1 1 OBD socket outlet

2 Brown (br) wire of OBD socket outlet/
pin 1
3 Crimp butt connector
4 Brown (br) wire of terminal 15
6 21 Red/white (rt/ws) wire of CLR mod- Connecting
ule/15 from cold start wiring harness terminal 15
14
1
rt/ws
21
0,75² 9

4 3 2 17

1 2 Route wiring harness 1 with wires 24 and

25 as well as temperature sensor RTD
in the engine compartment to the engine
control unit.

2 Wiring harness pass through Routing

wires in the
engine com-
partment

18

1 2 RTD 1 RTD wiring harness

2 Cable tie [3x]
RTD Temperature sensor
2

Securing
2 temperature
sensor

19
1 120-pin connector G
2 Engine control unit ECM

Detaching
engine con-
trol unit con-
1 nector

2 20

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1 Engine Control Unit Connection

for All Vehicles
1 120-pin connector G/ pin 95

View of en-
gine control
unit connec-
tor G, pin side

21
Remove the top connector cover on the
wiring side.

1 Violet/white (vi/ws) wire of engine

control unit connector G/ pin 95
View of engine
control unit
connector G,
wiring side
1

22

24 1 Detach part of the wiring harness wrap-

ping in front of the connector.
After finishing this, appropriately wrap
again and mount upper connector cover.

1 Crimp and shrink the butt connector [2x] Engine con-

25
2 Violet/white (vi/ws) wire of engine trol unit con-
2 control unit connector G/ pin 95 nection
1 3 120-pin engine control unit connector G
4 Violet/white (vi/ws) wire
24 Red (rt) wire of CLR module/W from
cold start wiring harness
25 Black (sw) wire of CLR module/A from
cold start wiring harness
4 3 23

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Final Work
Warning:
Final work is not carried out until the installation of the heater in the vehicle has been completed.
Check all electrical connections for firm seating. Insulate and tie back loose lines.
Spray the heater components with anti-corrosion wax (Tectyl 100K).

Webasto Thermo & Comfort SE

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

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