ALWAYS follow all Webasto installation and repair instructions and observe all warning instructions.

Transcription

1 Water Heater unit Feel drive Supplementary heating Thermo Top C e Installation instructions Dodge Caliber Diesel From model year 007 For left-hand drive vehicles only WARNING! Hazard warning: Incorrect installation or repair of Webasto heating systems may cause a fire or result in 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 company training and reby acquired required technical skills or if you do not have access to 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 warning instructions. Webasto does not accept any liability for defects and damage that are attributable to an installation by untrained staff. Ident. No.: 556A 0 fee Webasto AG

2 Table of Contents Validity Heater Unit / Installation Kit Foreword General Instructions Special Tools Explanatory Notes on Document 4 Preliminary work 5 Heater unit installation location 5 Electrical Connections 6 Manual air conditioning blower control 7 Time switch 8 Summer / winter switch option 8 Remote Start Option 8 Thermo Call Option 9 Preparing Installation Location 0 Preparing Heater Unit Installing Heater Unit 4 Fuel Connection 5 Exhaust System 8 Water Connection 0 Final Work Operating instructions for end customer Fastening Strap Template for Metering Pump 4 Tank Extracting Device Template 5 Validity Manufacturer Model Type EG-BE No. / ABE Daimler Chrysler (USA) Dodge Caliber PK e * 00 / 6 * 04 *... Engine type Engine model Power in kw Engine capacity in cm³ Code: BYL Diesel Vehicle and engine types, equipment variants as well as national specifications, which are not listed in se installation instructions, have not been tested. Installation according to se installation instructions may, however, be possible. The installation location of a time switch and summer / winter switch should be confirmed with end customer before installation. 556A

3 Heater Unit / Installation Kit Amount Description Order no.: LU Thermo Top C (D) with time switch 8944D LU Thermo Top C (D) with T80 remote start A Installation kit for Dodge Caliber Diesel 554A Foreword These installation instructions apply to Dodge vehicles with Caliber Diesel validity, see page from model year 007 and later, assuming technical modifications to vehicle do not affect installation, any liability claims excluded. Depending on vehicle version and equipment, modifications may be necessary during installation with respect to se installation instructions. However, where this is case stipulations in "installation instructions" and "operating and maintenance instructions" for Thermo Top C should be observed. The corresponding rules of technology and any information from vehicle manufacturer should be observed during installation work. General Instructions Installation should be carried out according to general, standard rules of technology. Unless specified orwise, fasten hoses, lines and cable harnesses to original vehicle lines and cable harnesses using cable clips. Sharp edges should be fitted with edge protectors (split open plastic hose). Spray unfinished body areas, such as bore holes, with anti-corrosion wax (Tectyl 00K, Order no. 9). Special Tools - Torque spanner for.0-0 Nm - Vice-grip wrench - Special Chrysler tool no: A

4 Explanatory Notes on Document To provide you with a quick overview of individual working steps, you will find an identification mark on outside top right corner of page in question. Mechanics Electrics Water connection Fuel connection Exhaust System Combustion air Special features are highlighted using following symbols: 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 manufacturer's vehiclespecific documents. Reference to a special technical feature. The arrow in vehicle icon indicates position on vehicle and viewing angle. 556A 4

5 Preliminary work WARNING! - Open tank cap, ventilate tank. - Close tank cap again. - Disconnect battery. - Pressure in cooling system! - Copy factory number from original type label to duplicate type label. - Remove years that do not apply from duplicate label. - Attach duplicate label (type label) in appropriate place. - Remove motor cover. - Remove air filter and suction tube - Remove front left wheel-house panel - Remove engine underride protection. - Remove rear left underride protection - Remove rear seat bench. - Open left tank mounting service lid - Remove tank mounting according to manufacturer's instructions. - Remove dashboard panel on driver s side. - Remove steering column panel on driver s side. Remove page "Operating instructions for end customer" and insert with vehicle operating instructions. Heater unit installation location Heater unit Installation location 556A 5

6 Electrical Connections Connecting ground wire Chassis ground point Ground wire Installing heater unit cable harness Heater unit cable harness to original vehicle lines rt sw Don't install metering pump cable harness until later toger with fuel pipe along original vehicle fuel lines on underbody Cable harness installation diagram bl br Fuse holder, K relay Cable harness feed-through Fuse holder retaining plate, bore hole Ø 4mm, 5.5x self-tapping screw Ø 4mm bore hole, 5.5x self-tapping screw K relay 4 Fuse holder Extend blower cable harness in interior with enclosed wires of same color! Blower control cable harness Original vehicle protective rubber sleeve Time switch cable harness 556A 6

7 Manual air conditioning blower control Webasto HG F 4 X Dodge Caliber 0 5 Circuit diagram gn/ws rt/ws F4 rt rt bl/ro a K 85 0 sw sw bl/ro + M - GM WG br Webasto components Vehicle components Colors and symbols HG Heater unit TT-C/E GM Blower motor rt red X 6-pin connector WG Resistor group ws white F Fuse 5A F4 Blower fuse sw black K Blower relay br brown gn green bl blue ro pink Legend X Splitting point Cable colors may vary. Connection to -pin connector from blower motor. Reconnect according to circuit diagram. 5 Blue/pink (bl/ro) wire from blower fuse Blue/pink (bl/ro) wire to pin connector 4 Black (sw) wire from relay K/0 5 Red (rt) wire to relay K/87a Connecting blower motor A 7

8 Time switch Time switch time switch 7 Summer / winter switch option Bore hole Ø mm, summer / winter switch summer / winter switch 8 Remote Start Option Position bracket according to illustration. Bolt M5x6, M5 flanged nut in previously drilled hole Receiver (to right next to steering column) receiver 9 Antenna antenna 0 556A 8

9 Temperature sensor for HTM00 only Temperature sensor, fasten as appropriate temperature sensor Thermo Call Option Ø 4mm bore hole, 5.5x self-tapping screws [4x each] Receiver (to left next to steering column) receiver Antenna antenna Tip switch tip switch 4 556A 9

10 Preparing Installation Location Rivet nut M8 in available bore hole Inserting rivet nuts 5 Loosely pre-assemble bracket and with bolt M8x0 on rivet nut. Copy hole image Copy hole image 6 Remove bracket Ø.5mm bore hole, tighten M8 rivet nut Inserting rivet nuts 7 Replace metal nut with body washer and M6 flanged nut at position. Replace nut 8 556A 0

11 Preparing Heater Unit Disassemble circulation pump, spring band clamps [x] will be used again. Disassemble circulation pump 9 Extension for circulation pump cable harness Slide on cable harness 0 B C X A D E a = 50mm b = 50mm c = 90mm d = 80mm e = 60mm Dispose of section X Cutting water hoses into sections X b c a d e X D Spring band clamp [x], from circulation pump Assemble hose C and D C 556A

12 Strut Loosely pre-fit ejot screw bolt Loosely preassemble strut on heater unit Connect circulation pump cable harness and extension with butt connectors 4 of same color. 4 Rubberized tube clamp Ø 48mm Circulation pump M6x0 bolt, flanged nut M6 on strut Preassembling circulation pump on strut 60mm 90mm Cut bracket to size 4 40mm 50mm 0mm 0mm Cut bracket to size 5 556A

13 Ejot screw bolt tightening torque 0 Nm! Insert two washers between heater unit and bracket in position. Ejot screw bolt [x] Ejot screw bolt, washer [x] Preassembling bracket on heater unit 6 Ø 7mm hose clamps [x] Connecting pipe 0x0 [x], Ø 7mm hose clamps [4x] A Preassemble water hose on heater unit E B 7 Spacer brackets [x] Inserting spacer bracket 8 M6x0 bolt, flanged nut M6 on strut Combustion air pipe Ø 7 mm hose clamp 4 Combustion air intake silencer 5 Ø 5mm tube clamp Preassembling fuel pipe A

14 Installing Heater Unit Prior to assembly, put on heater unit cable harness M8x0 bolt, spring washer, washer [x each] on prepared rivet nuts Heater Unit 0 M6 flanged nut to original vehicle stay bolts Strut Heater Unit 556A 4

15 Fuel Connection CAUTION! Open vehicle's tank-cap lock, ventilate tank and n re-close tank lock. Catch any fuel running off with an appropriate container. Install fuel line and metering pump cable harness so that y are protected against stone impact. Unless specified orwise, always fasten using cable clips! Fit fuel line and cable harness with edge protectors around sharp edges. WARNING! The fuel line and cable harness to metering pump should be installed based on cable harness installation diagram. Fuel line Hose section, Ø 0 mm hose clamps [x] Connectio n to heater Mecanyl fuel pipe, metering pump cable harness to original vehicle wires Installing lines 5 Note installation position of metering pump, see Installation Instructions. The installation location is on left before vehicle tank. Drill and bend fastening strap 4 according to template Rubberized tube clamp Original vehicle bolt 5 Silent block, flanged nut [x] Metering pump installation location A 5

16 Fuel line from heater unit on pressure side of metering pump [side with connector]. Hose section, Ø 0 mm hose clamps [x]. Metering pump cable harness, single wire seals [x], flat connector [x], connector housing Connecting to metering pump 5 Remove tank mounting according to manufacturer's instructions. Tank mounting Position Ø 6.7mm body washer according to illustration Copy hole image, Ø 6mm bore hole Fuel takeoff 6 Shape, cut into sections, and insert tank extracting device according to template, see Installation Instructions. Inserting tank extracting device 7 Install tank mounting according to manufacturer's instructions. Residual section of fuel line Tank extracting device 4 Hose section, Ø 0 mm hose clamps [x] Connecting and disconnect ing fuel pipe A 6

17 Fuel line from tank extracting device on intake side of metering pump [side without connector]. Check position of components; adjust if necessary. Check that y have free clearance. Hose section, Ø 0 mm hose clamps [x]. Connection to metering pump 9 556A 7

18 Exhaust System Exhaust pipe a = 80mm Exhaust end section b = 80mm Preparing exhaust pipe a b Angle bracket M6x0 bolt, M6 flanged nut on existing hole angle bracket 40 Exhaust silencer M6x0 bolt, M6 flanged nut on bracket spacer nut 4 4 Hose clamp Exhaust pipe Tube clamp, M6x0 bolt, flanged nut M6 on fastening strap 4 Fastening strap with holes 5 M6x5 bolt, flanged nut on existing hole exhaust pipe A 8

19 4 Exhaust pipe Tube clamp, M6x0 bolt, flanged nut M6 on fastening strap Slide rubber profile onto exhaust line. 4 Fastening strap with holes 5 M6x5 bolt, flanged nut on existing hole exhaust pipe 5 4 Align rubber profile according to illustration Exhaust pipe Hose clamp exhaust pipe 44 Drill Ø 4mm in underride protection at position and insert red rubber profile. Align exhaust end section flush with red (rt) rubber profile. exhaust end section A 9

20 Water Connection WARNING! Tighten all hose clamps to Nm. Any coolant running off should be collected using an appropriate container! Install hoses so that y are kink-free! Unless specified orwise, always fasten using cable clips! Position hose clamps so that no or hose can be damaged! The connection should be "inline" based on following diagram: Water installation diagram E Ø 7 B Ø 0x0 Ø 7 Ø 7 F Ø 7 Ø 7 Ø 0x0 Ø 0x0 Ø 7 Ø 7 A Ø 7 Ø 0x0 Ø 7 Ø 7 Ø 7 D C Ø 7 Ø 7 Symbol Description Symbol Description Position Description Connecting pipe Hose clamp Circulation pump 556A 0

21 Disconnect engine outlet hose from heat exchanger inlet supports. Dispose of spring band clamp. Splitting point 46 A Connect engine outlet hose section with hose A Connecting engine outlet E 47 F Connect hose F (enclosed 80 bend) with hose E and connect to heat exchanger inlet connecting piece. Before connecting, fill water hoses with coolant. Spacer bracket [x] Heat exchanger inlet connection A

22 Final Work WARNING! Reassemble disassembled components in reverse order. Check that all hose lines, clips, and all electrical connections are securely fastened. Secure all loose cables using cable clips. Only use manufacturer-approved coolant. Spray heating unit components with anti-corrosion wax (Tectyl 00K, Order No. 9). - Connect battery - Fill and bleed coolant circuit according to vehicle manufacturer s specifications. - Set time switch. - Set manual air conditioning or automatic air conditioning according to "operating instructions for end customer". - Check that auxiliary heating operates properly, see operating instructions / installation instructions. - Attach "Switch off auxiliary heating before re-fuelling" sticker onto left side of B-pillar. Body washer, bolt protector at bolt M6x5 Prepare to mount underride protection 49 Underride protection M6 flanged nut on bolt M6x5 underride protection 50 Feel drive Webasto AG PO Box 80-8 Stockdorf Hotline 0805 / Hotfax 095 / A Printed in Germany 0/007 Printed by: Steffen

23 Operating instructions for end customer Please remove page and add to vehicle operating instructions. Note: We recommend adjusting heating time to driving time heating time = driving time Example: For a driving time of 0 minutes (one way) we recommend not exceeding 0 minutes of power on time. It summer / winter switch option is installed for heater unit, switch this according to season. The heater unit will n heat when set to Winter and only blow air to ventilate passenger compartment when set to Summer. When leaving vehicle, deactivate interior monitoring according to vehicle user s manual in preparation for starting auxiliary heater. Before parking vehicle, make following settings: Blower set to level "" possibly "" Temperature to "max." Air outlet to windscreen For vehicles with manual air conditioning 5 556A

24 Fastening Strap Template for Metering Pump Ø 0.5mm 75 Torsion line 90 00mm Scale : Compare size of printed version with dimension lines. Permitted tolerance a maximum of %. Set printer settings to no margin or minimize margins and 00% of normal size. 00mm 0 556A 4

25 Tank Extracting Device Template 00mm Scale : Compare size of printed version with dimension lines. Permitted tolerance a maximum of %. Set printer settings to no margin or minimize margins and 00% of normal size. 00mm 0 556A 5