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Water Heater Unit
Thermo Top C Additional Heater
Thermo Top P Additional Heater
Installation Instructions
Dodge Journey (JC)
Gasoline and Diesel
from Model Year 2009
Left-hand drive vehicle
Manual air conditioning
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 suc-
cessfully 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 installa-
tion by untrained staff.
Ident. No.:1314082A_EN
e1
00 0002
e1
00 0104
Fee Euro 10.00
Feel the drive
© Webasto AG
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Table of Contents
Related Manuals for Webasto Dodge Journey (JC)
Summary of Contents for Webasto Dodge Journey (JC)
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Page 1: Installation Instructions
Manual air conditioning 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. -
Page 2: Table Of Contents
Dodge Journey (JC) Table of Contents Validity Coolant Heater Unit/Installation Kit Gasoline Foreword Diesel General Instructions Fuel Special Tools Gasoline Explanatory Notes on Document Diesel Preliminary Work Combustion air Heater unit installation location Exhaust gas Preparing electrical system Final Work Electrical system Template for Gasoline Fuel Standpipe Fan controller... -
Page 3: Heater Unit/Installation Kit
Dodge Journey (JC) Heater Unit/Installation Kit Quantity Description Order No.: Retail accessories with desired heater control See price list Installation kit for Dodge Journey (JC) Gasoline and Diesel 1314072A Heater unit recommended for the respective vehicle class: Vehicle Heater Unit Mid-size car, station wagon Thermo Top C Full-size car, van, offroader... -
Page 4: Explanatory Notes On Document
Dodge Journey (JC) 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. Mechanical system Electrical system Coolant Fuel Exhaust gas... -
Page 5: Preliminary Work
Dodge Journey (JC) 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. -
Page 6: Preparing Electrical System
Dodge Journey (JC) Preparing electrical system 1 Bracket of fuse and relay box 2 5.5 mm dia. hole Hole for angle bracket 1 M5x16 bolt, washer, flanged nut 2 Fuse holder 3 K3 relay 4 Retaining plate for fuse holder 5 Fuses pushed on Premount wiring har-... -
Page 7: Electrical System
Dodge Journey (JC) Electrical system Positive and ground connection Digital timer and summer/winter switch op- tion 1 Positive wire on original vehicle positive support point 2 Ground wire on original vehicle ground sup- 1 Summer/winter switch, drilled hole 12 mm dia. port point 2 Digital timer Do not install the metering pump... -
Page 8: Fan Controller
Fan controller Webasto Dodge Wiring dia- gram VSVM C114 4² 4² 4² 4² Webasto components Vehicle components Colors and symbols Heater unit TT-C/E Fan motor 6-pin heater unit connector WG Resistor group blue 25 A fuse Fan switch black Fan relay... -
Page 9: Remote Option (Telestart)
Dodge Journey (JC) Connection on 57-pin connector C114 2 in driver's side footwell. Produce connections as shown in wiring dia- gram. 1 Blue (bl) wire connector C114/30 Connect- 3 Red (rt) wire from K3/87a ing fan-mo- 4 Black (sw) wire from K3/30 5 Blue (bl) wire of fan motor Remote option (Telestart) Fasten receiver 1 with adhesive tape. -
Page 10: Remote Option (Thermo Call)
Dodge Journey (JC) Remote option (Thermo Call) Fasten receiver 1 with adhesive tape. Installing receiver 1 Antenna Installing antenna 1 Push button Installing push but- 1314082A_EN... -
Page 11: Preparing Installation Location
Dodge Journey (JC) Preparing installation location Remove original vehicle bolts at position 1 [2x] and discard. Removing bolts Drill out bracket 2 to 9.5 mm dia. at position 1 [2x]. Preparing bracket Copy hole pattern to battery tray at position 3 [2x] on frame side member. 1 M8x70 bolt, 40 mm shim 2 Bracket 4 M8x70 bolt, 40 mm shim, 5 mm shim... -
Page 12: Installing Heater Unit
Dodge Journey (JC) 1 M8x70 bolt, spring lockwasher, 40 mm shim 2 M6x70 bolt, spring lockwasher, 40 mm shim, 5 mm shim [2x each] 3 M8x70 bolt, spring lockwasher, 40 mm shim, 5 mm shim Installing bracket Glue on a foam strip in area of marking at po- sition 1 . - Page 13 Dodge Journey (JC) Insert two washers between heater unit and bracket 2 at Position 1 . 1 Ejot screw, washer [2x] 3 Ejot screw Installing heater unit 1 Ejot screw 2 Ejot stud Installing heater unit 1314082A_EN...
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Page 14: Coolant
Dodge Journey (JC) Coolant 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 cool- ant. - Page 15 Dodge Journey (JC) Gasoline a = 1300 b = 1440 Hose C = 90° elbow, 18x18 Cutting Discard section X coolant hoses to length Push braided protection hoses onto hose A and B and cut to length. Cut heat shrink plastic tubing to length. 1 50 mm long heat shrink plastic tubing [6x] Preparing coolant...
- Page 16 Dodge Journey (JC) 1 Original vehicle stud bolt, M6x40 spacer Installing spacer nut Connect- ing heater unit outlet Connect- ing heater unit inlet Glue on adhesive base 1 , secure hoses A and B with cable tie Routing in engine compart- ment 1314082A_EN...
- Page 17 Dodge Journey (JC) 1 Spacer nut, M6x20 bolt, spring lockwasher 2 48 mm dia. rubber-coated p-clamp Routing in engine compart- ment 1 Spacer nut, M6x20 bolt, spring lockwasher 2 48 mm dia. rubber-coated p-clamp Routing in engine compart- ment Disconnect hose to engine outlet/heat ex- changer inlet 2 at connection piece on heat exchanger inlet.
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Page 18: Diesel
Dodge Journey (JC) Ensure sufficient distance to neighboring components. 1 Hose of engine outlet 2 Original vehicle spring clip Connect- ing engine outlet Diesel a = 1400 b = 1440 Cutting Hose C = 90° elbow, 18x18 coolant Discard section X hoses to length Push braided protection hoses onto hose A... - Page 19 Dodge Journey (JC) Remove original vehicle nut at position 1 and discard. 1 Original vehicle stud bolt, M6x30 spacer 2 85 mm foam strip Installing spacer nut Remove original vehicle nut at position 1 and discard. 1 Original vehicle stud bolt, M6x40 spacer 2 Heat guard plate detached Installing spacer nut...
- Page 20 Dodge Journey (JC) Routing in engine compart- ment 1 Spacer nut, M6x20 bolt, spring lockwasher 2 48 mm dia. rubber-coated p-clamp Routing in engine compart- ment 1 Spacer nut, M6x20 bolt, spring lockwasher, 48 mm dia. rubber-coated p-clamp, heat guard plate Routing in engine compart-...
- Page 21 Dodge Journey (JC) Connect- ing heat exchanger inlet Ensure sufficient distance to neighboring components. 1 Spacer bracket 2 Original vehicle spring clip 3 Hose of engine outlet Connect- ing engine outlet 1314082A_EN...
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Page 22: Fuel
Dodge Journey (JC) 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. Un- less specified otherwise, always fasten using cable ties. -
Page 23: Gasoline
Dodge Journey (JC) 1 Drill 9.1 mm dia. hole; install rivet nut Installing rivet nut 1 Silent block, flanged nut, rivet nut 2 Metering pump 3 Rubber-coated pipe clamp Installing metering pump 1 Wiring harness of metering pump, connec- tor mounted 2 Wiring harness of metering pump, fuel line in corrugated tube 3 Fuel line... - Page 24 Dodge Journey (JC) Shape fuel standpipe 1 according to tem- plate, cut to length and install. Installing fuel stand- pipe Install fuel-tank sending unit 1 in accordance with manufacturer's specifications. Install fuel tank in accordance with manufacturer's spec- ifications. 2 90° molded hose Connect- 3 10 mm dia.
- Page 25 Dodge Journey (JC) Shape fuel standpipe 1 according to tem- plate, cut to length and install. Installing fuel stand- pipe Install fuel-tank sending unit 1 in accordance with manufacturer's specifications. Install fuel tank in accordance with manufacturer's spec- ifications. 2 90° molded hose Connect- 3 10 mm dia.
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Page 26: Combustion Air
Dodge Journey (JC) Combustion air 1 6.5 mm dia. hole Hole in bumper trim 1 Muffler 2 M6x20 bolt, p-clamp, flanged nut 3 Combustion air pipe 4 27 mm dia. clamp Installing muffler 1314082A_EN... -
Page 27: Exhaust Gas
Dodge Journey (JC) Exhaust gas 1 Exhaust pipe a = 360 2 Exhaust end section b = 195 Preparing exhaust Discard section X pipe 1 Hose clamp 2 Exhaust manifold 3 M6x30 spacer nut, Ejot stud Installing exhaust manifold 1 P-clamp 2 Hose clamp [2x] 3 Exhaust pipe 4 Muffler... -
Page 28: Final Work
Align exhaust end section 3 flush on red rub- ber isolator 2 . 1 Underride protection Mounting rubber iso- lator Feel the drive Webasto AG Postfach 80 - 82132 Stockdorf Hotline 01805 / 932278 - Hotfax 0395 / 5592-353 http://www.webasto.de Printed in Germany 12/2008 Printing: Stef-... -
Page 29: Template For Gasoline Fuel Standpipe
Dodge Journey (JC) Template for Gasoline Fuel Standpipe 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 mar- gins” and 100% of the normal size. 100 mm 1314082A_EN... -
Page 30: Template For Diesel Fuel Standpipe
Dodge Journey (JC) Template for Diesel fuel standpipe 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 mar- gins” and 100% of the normal size. 100 mm 1314082A_EN... -
Page 31: Operating Instructions For End Customer
Dodge Journey (JC) 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.