Water Heater Unit

Water Heater Unit

Water Heater Unit

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. 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 technical 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 installation by untrained staff.

Water Heater Unit Installation Instructions Ident. No.:1313046C_EN Fee Euro 10.00 © Webasto AG Peugeot 308 Gasoline and Diesel from Model Year 2007 Left-hand drive vehicle Manual transmission Feel the drive Thermo Top E Additional Heater e1 00 0003 Thermo Top C Additional Heater e1 00 0002 Thermo Top P Additional Heater e1 00 0104

Water Heater Unit

Peugeot 308 1313046C_EN 2 Table of Contents 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 a digital timer and summer/winter switch should be confirmed with the end customer before installation. Manufacturer Model Type EG-BE No./ABE Peugeot 308 4 e1 * 2001/116 * 0340 . . Peugeot 308 4 e1 * 2001/116 * 0362 . . Engine type Engine model Output in kW Displacement in cm³ 5FW Gasoline 88 1598 9 Hz Diesel 81 1560 RHR Diesel 100 1997 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 8 Fan controller for manual air conditioning 9 Automatic air-conditioning fan controller 11 Digital timer, summer/winter switch option 14 Remote option (Telestart) 14 Preparing bracket 15 Installation of heater unit on 1.6 liter diesel 15 Installation of heater unit on 2.0 liter diesel 17 Installation of heater unit on 1.6 liter gasoline 19 Coolant on 1.6 diesel 21 Coolant on 2.0 diesel 24 Coolant for gasoline engine 28 Fuel 31 Exhaust gas 34 Combustion air on diesel engine 36 Combustion air on gasoline engine 37 Final Work 38 Operating Instructions for End Customer 39 Template for Perforated Fastening Strap 40 Template for Gasoline Fuel Standpipe 41

Water Heater Unit

Peugeot 308 1313046C_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 308 Gasoline and Diesel vehicles - for validity, see page 2 - from model year 2007 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 the "installation instructions" and "operating and maintenance instructions" 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 specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses using cable ties. Sharp edges should be fitted with edge protectors (split-open plastic 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 with desired heater control See price list and 1 Installation Kit for Peugeot 308 Gasoline, Air Conditioning 1313392A or 1 Installation Kit for Peugeot 308 Diesel, Air Conditioning 1313081B or 1 Installation Kit for Peugeot 308Gasoline, Automatic Air- Conditioning 1313391A or 1 Installation Kit for Peugeot 308Diesel, Automatic Air- Conditioning 1313037A Vehicle Heater unit Compact car Thermo Top E Mid-size car, station wagon Thermo Top C Full-size car, van, offroader Thermo Top P

Water Heater Unit

Peugeot 308 1313046C_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. Reference to general installation instructions of Webasto 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 Water 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.

Water Heater Unit

Peugeot 308 1313046C_EN 5 Preliminary Work WARNING! - Open fuel tank cap, ventilate tank. - Close the tank cap again. - 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. - Completely remove the battery. - Remove the air filter together with the intake hose. - Remove the coolant reservoir cap - Remove the underride protection - Remove the radio - Remove the A/C control panel in accordance with the manufacturers specifications.

- Remove the lower instrument panel trim on the driver's side. - Remove the foot airbag.

Remove page 39 "Operating Instructions for End Customer" and add to the vehicle operating instructions. Heater unit installation location 1 Heater unit Installation location 1 1

Water Heater Unit

Peugeot 308 1313046C_EN 6 Preparing electrical system Manual air conditioning Preparing lines Produce connections as shown in wiring diagram. Pull wire section 1 into included protective sleeving [2x]. Remove line not required 2 from relay socket. Preparing K3 relay Connect wires to IPCU. IPCU view on contact side! Preassem- bling IPCU 3000 1 gn/ws 0,5² 2 250 br 0,5² 3 200 sw 0,5² 4 200 rt 0,5² 86 85 30 87a 87 K3 1 2 86 85 A E 15 IPCU 3 4 2 A 15 86 85 E

Water Heater Unit

Peugeot 308 1313046C_EN 7 Automatic air-conditioning Wire section 9 will be required later for ground connection of additional relay. Cutting wires to length Produce connections as shown in wiring diagram. Pull wire section 1 into included protective sleeving [2x]. Remove line not required 2 from relay socket. Preparing K3 relay Connect wires to IPCU. IPCU view on contact side! Preassem- bling IPCU Produce connections as shown in wiring diagram. Preparing additional relay K3.1 3000 1 gn/ws 0,5² 2 150 br 0,5² 9 850 3 150 sw 0,5² 6 150 4 150 rt 0,5² 5 150 150 150 7 8 86 85 30 87a 87 K3 1 2 86 85 A E 15 IPCU 5 3 4 2 A 15 86 85 E 8 86 85 30 87a 87 K3.1 7 6

Water Heater Unit

Peugeot 308 1313046C_EN 8 Electrical system Ground wire 1 Ground wire on original vehicle ground support point Positive wire 1 Positive wire on original vehicle positive support point Wiring harness installation diagram Fuse holder, relay K3 1 4 mm dia. hole, 5.5x13 self-tapping screw, retaining plate of fuse holder, plastic nut 2 4 mm dia. hole, 5.5x13 self-tapping screw, plastic nut 3 K3 relay 4 Fuse holder Wiring harness pass through 1 Protective rubber plug 2 Adhesive socket with cable tie 3 Protective rubber plug 4 Wiring harnesses of fan controller, digital timer 2 1 2 3 1 Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody 4 4 3 1 2 5 4 2 3 1

Water Heater Unit

Peugeot 308 1313046C_EN 9 Fan controller for manual air conditioning Wiring diagram Webasto components Vehicle components Colors and symbols Legend HG Heater unit TT-C/P 8050 Fan motor rt red X1 6-pin heater unit connector 8045 Fan controller ws white F3 25 A fuse 8025 Air-conditioning control panel sw black K3 Fan relay F11 Fuse br brown IPCU Pulse width modulator IC26(A) 6-pin connector gn green A Fan adapter 2V NR 2-pin connector 6 V NR 6-pin connector PSF 1 Main power supply IPCU adjustment values: Duty cycle: 100 % Frequency: 14000 Hz Voltage: 2.7 V X Cutting point Function: High-side Wiring colors may vary.

gn/ ws sw rt/ws Webasto 31 30 15 Peugeot rt sw gn/ws F3 br ws ws 1 2 4 86 85 30 87a 87 K3 3 4² 0,5² 0,5² 0,5² 0,5² HG X1 4 8025 86 85 E A 15 IPCU br 0,5² 2V NR 1 2 8050 M 6V NR 5 R7 2 2V NR F11 PSF 1 rt 4² rt 4² 6V NR 4 5 2 1 8045 6 3 IC26(A) 3 4 0,5² A

Water Heater Unit

Peugeot 308 1313046C_EN 10 Connection on 6-pin connector 3 of IC26(A). Produce connections as shown in wiring diagram. 1 Fan adapter 2 Red (rt) wire of PSF 1, Pin 2 4 Red (rt) wire of connector IC26(A)/3 5 Black (sw) wire from K3/30 Connec- tion of con- nector IC26A Mount green/white (gn/ws) wire 2 on IPCU/86 before installation. Cut Velcro strip in middle. Fasten IPCU 1 on carrier. 2 Velcro strip Installing IPCU Connection to 6-pin connector 5 from A/C control element. Produce connections as shown in wiring diagram. 1 White (ws) wire 8045/5 2 Black (sw) wire of IPCU/A 3 Red (rt) wire of IPCU/E 4 White (ws) wire 8025/5 Connect- ing IPCU 1 Original vehicle ground support point on center console 2 Brown (br) wire of IPCU/85 Ground connection of IPCU 6 1 4 5 3 2 7 1 3 2 8 1 4 5 2 3 9 1 2

Peugeot 308 1313046C_EN 11 Automatic air-conditioning fan controller Wiring diagram Webasto components Vehicle components Colors and symbols Legend HG Heater unit TT-C/P 8050 Fan motor rt red X1 6-pin heater unit connector 8045 Fan controller ws white F3 25 A fuse 8080 Air-conditioning control panel sw black K3 Fan relay F11 Fuse br brown IPCU Pulse width modulator F13 Fuse gn green K3.1 Additional relay MF7 Fuse ge yellow A Fan adapter IC26(A) 6-pin connector ro pink 2V NR 2-pin connector 2V GR 2-pin connector IPCU adjustment values: 6 V NR 6-pin connector Duty cycle: 75 % 6 V GR 6-pin connector Frequency: 400 Hz 40 V BE 40-pin connector Voltage: 12 V PSF 1 Main power supply X Cutting point Function: Low-side BSF 1 Central electrical box for passenger compartment Wiring colors may vary.

gn/ ws sw rt/ws Webasto 31 30 15 Peugeot rt rt sw gn/ws F3 86 85 30 87a 87 K3.1 rt 9 br ge ge ro 7 6 1 2 4 86 85 30 87a 87 K3 3 sw rt 4² 0,5² 0,5² 0,5² 0,5² HG X1 4 20 17 8080 40V BE 86 85 E A 15 IPCU 8 br rt 5 0,5² 0,5² 0,5² 0,5² 0,5² 2V NR 1 2 8050 M 6V NR 4 1 R7 2 2V NR F11 PSF 1 MF7 rt 0,5² 0,5² br rt 4² rt 4² 6V NR 4 5 2 1 8045 6 3 IC26(A) 3 4 R7 11 16V GR F13 BSI 1 2 2V GR 0,5² 0,5² A

Peugeot 308 1313046C_EN 12 Connection on 6-pin connector 3 of IC26(A). Produce connections as shown in wiring diagram. 1 Fan adapter 2 Red (rt) wire of PSF 1, Pin 2 4 Red (rt) wire of connector IC26(A)/3 5 Black (sw) wire from K3/30 Connec- tion of con- nector IC26A Mount green/white (gn/ws) wire 2 on IPCU/86 before installation. Cut Velcro strip in middle. Fasten IPCU 1 on carrier. 3 Velcro strip Installing IPCU Connection onOBD socket outlet 1. Produce connections as shown in wiring diagram. 2 White (ws) wire of OBD socket outlet, Pin 1 3 Socket of OBD socket outlet 4 White (ws) wire of OBD socket outlet, Pin 1 5 Red (rt) wire IPCU/15 Connec- tion of Ter- minal 15 Connection on 40-pin connector 4 from A/C control panel (remove connector).

Produce connections as shown in wiring diagram.

1 Black (sw) wire of IPCU/A 2 Yellow (ge) wire 8080/20 3 Yellow (ge) wire 8045/5 5 Red (rt) wire of IPCU/E Connect- ing IPCU 10 1 4 5 3 2 11 1 3 2 12 1 4 3 2 5 13 2 4 5 1 3

Peugeot 308 1313046C_EN 13 Before installing, mount brown (br) wire [2x] (wire section 2 and 9) on K3.1/85 and red (rt) wire (wire section 8) on K3.1/86. Fasten additional relay K3.1 2 on socket of IPCU. 1 Velcro strip Installing K3.1 Connection to 6-pin connector 3 from A/C control element. Produce connections as shown in wiring diagram. 1 Red (rt) wire to K3.1/87 2 Red (rt) wire BSI F13 4 Red (rt) wire 8080/1 5 Black (sw) wire K3.1/30 Connec- tion of K3.1 1 Original vehicle ground support point on center console 2 Brown (br) wire K3.1/85 Ground connection of K3.1 14 1 2 15 1 3 2 5 4 16 1 2

Peugeot 308 1313046C_EN 14 Digital timer, summer/winter switch option 1 Digital timer 2 Summer/winter switch, drilled hole 12 mm dia. Installing digital timer Remote option (Telestart) 1 Fasten receiver with Velcro strip Installing receiver 1 Antenna Installing antenna Temperature sensor for HTM100 only 1 Fasten temperature sensor with Velcro strip Installing tempera- ture sensor 1 17 1 1 18 1 19 1 20

1313046C_EN 15 Peugeot 308 Preparing bracket 1 M6x12 bolt, flanged nut [2x each] 2 Bracket A 3 Bracket B Preparing bracket Installation of heater unit on 1.6 liter diesel Preparing installation location Copy hole pattern to bracket of air intake pipe 1 at position 3.

Then remove bracket. Original vehicle bolt 2 will be reused. Copying hole pattern Remove stiffener on bracket of air intake pipe at position 1 as shown. 2 Position large diameter washer 3 Copy hole pattern Preparing bracket of air intake pipe 1 14 mm dia. hole 2 7 mm dia. hole Drilling bracket of air intake pipe 21 2 1 3 1 22 1 3 2 23 1 1 2 1 3 24 1 2

1313046C_EN 16 Peugeot 308 Cut plastic angle bracket off bracket of air intake pipe at position 1 and discard. Preparing bracket of air intake pipe 1 M6x20 bolt [2x] 2 Copy hole pattern to center 3 Copy hole pattern Loosely mount bracket Remove bracket. 1 9.1 mm dia. hole; rivet nut [2x each] Installing rivet nut Installing bracket Loosely mount bracket. 1 M6x40 bolt, spring lockwasher, 20 mm shim on rivet nut Installing bracket 25 1 1 26 2 1 3 1 27 1 1 28 1

Peugeot 308 1313046C_EN 17 Insert two washers between bracket and large diameter washer at position 2.

Then tighten all connections. 1 Original vehicle bolt on existing threaded hole 2 M6x20 bolt, spring lockwasher, large diameter washer, washer [2x] on existing threaded hole 3 M6x25 bolt, spring lockwasher, large diameter washer on rivet nut Installing bracket Installing heater unit Insert two washers between heater unit and bracket at position 1. 1 Ejot screw, washer [2x] 2 Ejot screw [2x] Installing heater unit 1 Ejot screw Installing heater unit Installation of heater unit on 2.0 liter diesel Preparing installation location Remove charge-air tube with bracket 1. Original vehicle bolts at Position 2 will be reused.

Removing bracket 29 3 2 1 30 1 2 2 31 1 32 1 2 2

1313046C_EN 18 Peugeot 308 Loosely mount premounted bracket (A and B) 5 together with bracket of charge-air tube 2. 1 M6x20 bolt, spring lockwasher, large diameter washer on existing threaded hole 3 Original vehicle bolt [2x] 4 Copy hole pattern Loosely mount bracket Remove bracket. 1 Drill 9.1 mm dia. hole; rivet nut Installing rivet nut Installing bracket Install premounted bracket (A and B) 5 together with bracket of charge-air tube 2. 1 M6x20 bolt, spring lockwasher, large diameter washer on existing threaded hole 3 Original vehicle bolt [2x] 4 M6x40 bolt, spring lockwasher, large diameter washer, 20 mm shim on rivet nut Installing bracket 1 Charge-air tube Installing charge-air tube 33 3 1 3 4 2 5 34 1 35 3 1 3 4 2 5 36 1

1313046C_EN 19 Peugeot 308 Installing heater unit Insert two washers between heater unit and bracket at position 1. 1 Ejot screw, washer [2x] 2 Ejot screw Installing heater unit 1 Ejot screw Installing heater unit Installation of heater unit on 1.6 liter gasoline Preparing installation location Remove bracket of resonator 1. Original vehicle bolts at Position 2 will be reused. Removing bracket Loosely mount premounted bracket (A and B) 5 together with bracket of resonator 2. 1 M6x20 bolt, spring lockwasher, large diameter washer on existing threaded hole 3 Original vehicle bolt [2x] 4 Copy hole pattern Loosely mount bracket 37 1 2 2 38 1 39 1 2 2 40 3 1 3 4 2 5

1313046C_EN 20 Peugeot 308 Remove bracket. 1 Drill 9.1 mm dia. hole; rivet nut Installing rivet nut Installing bracket Install premounted bracket (A and B) 5 together with bracket of charge-air tube 2. 1 M6x20 bolt, spring lockwasher, large diameter washer on existing threaded hole 3 Original vehicle bolt [2x] 4 M6x40 bolt, spring lockwasher, large diameter washer, 20 mm shim on rivet nut Installing bracket Installing heater unit Insert two washers between heater unit and bracket at position 1. 1 Ejot screw, washer [2x] 2 Ejot screw Installing heater unit 1 Ejot screw Installing heater unit 41 1 42 3 1 3 4 2 5 43 1 2 2 44 1

Peugeot 308 1313046C_EN 21 Coolant on 1.6 diesel WARNING! Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-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 diagram All hose clamps = 20-27 mm dia.! All connecting pipes = Ø 18x20. 1 = Original vehicle spring clip, 2 = black (sw) rubber isolator. A B C 1 2 2

Peugeot 308 1313046C_EN 22 b = 540 c = 410 Hose A =180° molded hose Discard section X Cutting coolant hoses to length Pull original vehicle hose off engine outlet/heat exchanger inlet 1 and remove from hose bracket 2. Original vehicle spring clip will be reused. Cutting point 1 Original vehicle spring clip 2 Hose on heat exchanger inlet 3 Black (sw) rubber isolator with cable tie on battery carrier Preparing hose sections Connect- ing heater unit C B X X X A 45 1 2 46 2 A 3 1 47 B C

Peugeot 308 1313046C_EN 23 1 Black (sw) rubber isolator on hose A Connect- ing engine outlet Connect- ing heat exchanger inlet Ensure sufficient distance to neighboring components.

Aligning hoses 48 B 1 A 49 C 50 B C A

Peugeot 308 1313046C_EN 24 Coolant on 2.0 diesel WARNING! Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-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 diagram All hose clamps = 20-27 mm dia.! All connecting pipes = 20x20 dia.. 1 = Black (sw) rubber isolator .

A B C D 1

Peugeot 308 1313046C_EN 25 a = 600 c = 100 d = 520 Discard section X Cutting coolant hoses to length Remove original vehicle hose on engine outlet/heat exchanger inlet 1.

Cutting point Remove braided protection hose. 1 Engine-outlet hose section 2 Discard hose section 3 Hose section of heat exchanger inlet Separating hose Remount hose sections. 1 Connecting pipe [2x] 2 Clamp [2x] Preparing hose sections B A C X D 51 1 52 3 1 2 53 1 1 2 2

Peugeot 308 1313046C_EN 26 1 Angle bracket 2 48 mm dia. rubber-coated p-clamp 3 M6x20 bolt, flanged nut 4 Mount M6x20 bolt, flanged nut in existing hole Installing p-clamp Route hose A through rubber-coated p- clamp. 1 Engine-outlet hose section 2 Black (sw) rubber isolator on hose section of heat exchanger inlet Connect- ing engine outlet Connect- ing heater unit inlet Connect- ing heater unit outlet 54 2 4 1 3 55 A 2 1 56 A B 57 C

Peugeot 308 1313046C_EN 27 1 Rubber-coated pipe clamp Routing in engine compart- ment Ensure sufficient distance to neighboring components.

1 Hose section of heat exchanger inlet Connect- ing heat exchanger inlet 58 1 C D A 59 1 D

Peugeot 308 1313046C_EN 28 Coolant for gasoline engine WARNING! Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-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 diagram All hose clamps = 20-27 mm dia.! All connecting pipes without a specific designation = dia. 18x20. 1 = Black (sw) rubber isolator .

A B C 1 1 Ø 18x18

Peugeot 308 1313046C_EN 29 b = 770 c = 620 Hose A =180° molded hose Discard section X Cutting coolant hoses to length Cut off original vehicle hose on engine outlet/heat exchanger inlet at marking. 1 Engine-outlet hose section 2 Hose section of heat exchanger inlet Cutting point 1 Engine-outlet hose section 2 Hose section of heat exchanger inlet Preparing hose sections Connect- ing heater unit C B X X X A 60 1 2 61 2 A 1 62 B C

Peugeot 308 1313046C_EN 30 1 Black (sw) rubber isolator on hose C 2 Hose on heat exchanger inlet Connect- ing heat exchanger inlet 1 Black (sw) rubber isolator on hose B Connect- ing engine outlet Align and position black (sw) rubber isolator 1 [2x].

Ensure sufficient distance to neighboring components. Aligning hoses 63 C 1 2 64 B 1 A 65 C A A 1 1

Peugeot 308 1313046C_EN 31 Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. 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. Unless 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.

1 Hose section, 10 mm dia. clamp [2x] 2 Fuel line in corrugated tube Connec- tion to heater unit Route fuel line, wiring harness of metering pump in corrugated tube 1 to firewall on right- hand side of vehicle and further in line duct on underbody to installation location of metering pump.

Installing lines 1 Fuel line from heater unit 2 Line duct 3 Metering pump wiring harness Installing lines 66 2 1 67 1 68 1 2 3

Peugeot 308 1313046C_EN 32 1 Angle bracket 2 Silent block, flanged nut [2x] 3 Rubber-coated pipe clamp 4 Metering pump 5 Original vehicle bolt Installing metering pump Check the position of the components; adjust if necessary. Check that they have free clearance. 1 Wiring harness of metering pump, connector mounted 2 Fuel line from heater unit 3 Hose section, 10 mm dia. clamp [2x] 4 Hose section, 10 mm dia. clamp [2x] 5 Fuel line Connect- ing to me- tering pump Fuel removal on diesel engines Cut off fuel supply line 2 at Position 1. 1 Fuel standpipe, 10 mm dia. clamp [2x] 3 90° molded hose, 10 mm dia.

clamp [2x] 4 Fuel line Removing fuel Fuel removal on gasoline engines Remove fuel-tank sending unit 1 in accordance with manufacturer's specifications.

2 5 mm dia. large diameter washer 3 Copy hole pattern, 6 mm dia. hole Removing fuel 69 1 2 5 3 4 70 4 1 5 2 3 71 3 1 2 4 72 1 2 3

Peugeot 308 1313046C_EN 33 Shape fuel standpipe 1 according to template, cut to length and install. 2 Fuel-tank sending unit Installing fuel standpipe Install fuel-tank sending unit 3 in accordance with manufacturer's instructions. 1 Fuel standpipe 2 Fuel line 4 Hose section, 10 mm dia. Caillau clamp Connect- ing fuel line 73 1 2 1 74 2 1 4 3

Peugeot 308 1313046C_EN 34 Exhaust gas 1 Exhaust pipe a = 330 2 Exhaust end section b = 260 Discard section X Preparing exhaust pipe Bend perforated bracket 1 according to template.

2 Original vehicle bolt Installing perforated bracket 1 Red (rt) rubber isolator 2 Exhaust pipe 3 Hose clamp Installing exhaust pipe Secure original vehicle wiring harness 1 with cable tie. 2 M6x20 bolt, flanged nut 3 Muffler 4 Hose clamp Installing muffler a B 1 2 X 1 2 75 1 2 3 76 2 4 77 3 1

Peugeot 308 1313046C_EN 35 Ensure sufficient distance to neighboring components. 1 Hose clamp 2 Exhaust end section Installing exhaust end section 42 mm dia. hole at Position 3 in underride protection 1. Align exhaust end section 3 flush on red rubber isolator 2. Position- ing rubber isolator 2 1 78 1 2 3 79

Peugeot 308 1313046C_EN 36 Combustion air on diesel engine 1 27 mm dia. clamp 2 Combustion air pipe Installing combus- tion air pipe 1 M6x25 bolt, 10 mm shim, flanged nut 2 52 mm dia. clamp 3 Muffler 4 48 mm dia. rubber-coated p-clamp on charge-air hose Installing muffler 80 1 2 81 1 3 2 4

Peugeot 308 1313046C_EN 37 Combustion air on gasoline engine 1 Combustion air pipe a = 300 Discard section X Cutting combus- tion air pipe to length 1 27 mm dia. clamp 2 Combustion air pipe Installing combus- tion air pipe 1 48 mm dia. rubber-coated p-clamp on resinator hose 2 52 mm dia. clamp 3 Muffler 4 M6x25 bolt, flanged nut Installing muffler a 1 X 82 1 2 83 1 2 4 3

Peugeot 308 Feel the drive Webasto AG Postfach 80 - 82132 Stockdorf Hotline 01805 / 932278 - Hotfax 0395 / 5592-353 http://www.webasto.de Printed in Germany 03/2008 Printing: Steffen 1313046C_EN Final Work WARNING! Reassemble the disassembled components 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 the 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.

- Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Check the proper operation of the additional heater, see the operating instructions/installation instructions. - Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar.

Peugeot 308 1313046C_EN 39 Operating Instructions for End Customer 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. Before parking the vehicle, make the following settings: 1 Air outlet to windshield 2 Fan speed "1" or "2" 3 Set temperature to "max." Manual air condition- ing 1 Air outlet to windshield 2 Set temperature to "HI“ Automatic air-condi- tioning 84 3 1 2 85 2 2 1

Peugeot 308 1313046C_EN 40 100 mm 100 mm 90° 75 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 “minimize margins” and 100% of the normal size. Template for Perforated Fastening Strap

Peugeot 308 1313046C_EN 41 100 mm 100 mm 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 “minimize margins” and 100% of the normal size. Template for Gasoline Fuel Standpipe