Professional Documents
Culture Documents
E1
Thermo Top Evo Parking Heater 00 0258
Installation Documentation
Peugeot 508
Validity
Manufacturer Model Type EG-BE No. / ABE
Peugeot 508 8 e2 * 2007 / 46 * 0080 *...
Peugeot 508 SW 8 e2 * 2007 / 46 * 0080 *...
SG = Manual transmission
AT = Automatic transmission
Table of Contents
Validity 1 Preparing Installation Location 10
Necessary Components 2 Installing Heater 10
Installation Overview 2 Coolant Circuit 2.0 D 11
Information on Total Installation Time 2 Coolant Circuit 1.6 B and 2.2 D 14
Information on Operating and Installation Instructions 3 Fuel 19
Information on Validity 4 Final Work 23
Technical Information 4 Template for Petrol Fuel Standpipe 24
Explanatory Notes on Document 4 Template for Diesel Fuel Standpipe 25
Preliminary Work 5 Operating Instructions for End Customer 26
Heater Installation Location 5
Electrical System 6
Fan Controller 7
Digital Timer 9
Remote Option (Telestart) 9
Necessary Components
• Delivery scope of Peugeot 508 HDI Thermo Top Evo Diesel: 1317544B
• Delivery scope of Peugeot 508 HDI Thermo Top Evo Petrol: 1317545B
• 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
5
Legend:
1. Heater
2. Engine compartment fuse 2
4
holder
3. Circulating pump
3
4. Digital timer
5. Metering pump 1
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.
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
Information on Validity
This installation documentation applies to Peugeot 508 Petrol and diesel vehicles - for validity, see page 1 - from mod-
el 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 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
• 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
• Webasto Thermo Test Diagnosis with current software
Dimensions
• All dimensions are in mm
Tightening torque values
• Tightening torque values of 5x13 heater 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.
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.
Software
Preliminary Work
Vehicle
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.
Installation
location
1 1
Electrical System
Fuse holder of engine compartment Positive and earth wire
1 Original vehicle bolt, large diameter washer 1 Positive wire
2 M5x16 bolt, large diameter washer [2x], re- 2 Earth wire on original vehicle earth support
taining plate of fuse holder, nut point
3 Fuses F1-2 attached (replace 30A F2 with 1A)
4 Angle bracket
1 2 1 2
4 2 3
Wiring har-
ness rout-
ing
diagram
Do not install the metering pump
wiring harness until later togeth-
er with fuel line in the corrugated
tube along the original vehicle
lines on the underbody
1 1
2 4 3 2 5
Fasten wiring harness of engine compartment 1 Insert protective rubber plug in hole
fuse holder 2 with adhesive base 1 and cable tie 2 Wiring harness of engine compartment fuse holder
[total 4x each] in the wheel well. 3 Adhesive base, cable tie
Fan Controller
Webasto Peugeot
30
15
Wiring dia-
HG gram
X2 1 2 2 5 X1
F2 F1
rt
4²
3
1
gn/ws
0,75²
4
rt/sw ge
0,5² 0,5²
br br
0,5² 2 0,5²
ST A 34
! BSI
X10
31
Pulling off
1 and dis-
mantling
connector
of BSI
2 7
2 8
Complete connector of BSI 1 and reinsert into
socket of BSI 2.
2 Connec-
tion of BSI
connector
1 9
Digital Timer
1 Digital timer
Mounting
digital tim-
er
1 10
Mounting
receiver
1 11
1 Antenna
Mounting
antenna
1 12
Installing
tempera-
ture sensor
13
5 14
1 1 Installing Heater
Mount stud bolts from bracket in existing
holes.
15
16
Hose rout-
ing dia-
gram
Ø 25
1
Ø 25
2
B
All spring clips without a specific designation = 27 mm dia. 1 = Original vehicle coupling.
Connecting pipe = 18x18 dia. 2 = Black (sw) rubber isolator .
Discard section X.
A = 740
B = 640
A B
X
Cutting
hoses to
length
1 1
1 Remove original vehicle hose 1. Remove
braided protective hose and discard.
Removing
hose
17
5 4 3 2 18
Connect-
ing engine
outlet and
2 heat ex-
B
changer in-
let
A 19
Routing in
engine
compart-
ment
A 20
Routing in
engine
compart-
ment
A 21
Connect-
ing heater
A 22
Hose rout-
ing dia-
gram
A
Ø 25
Ø 25 Ø 25
Ø 25
Ø 25 Ø 25
C
B
Discard section X.
Hose A =180° elbow
B C
X
1.6 Petrol
B = 890
C = 800 Cutting
hoses to
2.2 Diesel length
B = 750
C = 630
X
A
1 1 All vehicles
1 1
C
Premount-
ing hoses
A B 23
1 2 1.6 Petrol
24
Connec-
tion of heat
C exchanger
inlet
1 25
Connect-
ing engine
C A outlet
B 26
B 3 27
Routing in
engine
compart-
ment
B 28
Connect-
ing heater
B 29
1 2.2 Diesel
30
B
Connect-
ing engine
outlet
1 31
Connec-
tion of heat
exchanger
inlet
C 32
Routing in
engine
compart-
ment
2 B 33
Routing in
engine
compart-
ment
B 34
Connect-
ing heater
B 35
Fuel
CAUTION!
Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.
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.
Connect-
ing heater
36
Routing
wire
37
1 Petrol
Routing
wire
1
38
6 5 39
Connect-
ing meter-
ing pump
40
2 Flanged nut
3 Copy hole pattern, 6 mm dia. hole
Fuel ex-
traction
3
2 41
Cut fuel standpipe 1 to length according to
template and install.
Installing
1 fuel stand-
pipe
42
3 2 1 43
Diesel
Routing
lines
1
44
2 45
1 2 1 Metering pump
2 Bracket of metering pump
3 M6x25 bolt, large diameter washer
Mounting
metering
pump
3 46
4 47
3 48
Shape fuel standpipe 1 according to tem-
plate, cut to length and install.
1 Installing
fuel stand-
pipe
49
50
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 using diag. box on parking heater.
• 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 1 Underride protection
2 Cut out exhaust outlet along perforation
Cutting out
underride
protection
2 51
Mount underride protection 1 (exhaust end
section centred in recess).
Mounting
underride
protection
1
2 52
100mm
Scale 1:1
100mm
Scale 1:1
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.
Fuses of
engine
compart-
ment
53