Webasto BlueHeat Installation Instructions Manual
Jeep 2002 grand cherokee;
jeep 2003 grand cherokee
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Also See for BlueHeat:
- Manual (26 pages) ,
- Installation instructions manual (24 pages) ,
- Owner's manual (4 pages)
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Summary of Contents for Webasto BlueHeat
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Page 1: Installation Instructions
BlueHeat Coolant Heater Jeep Grand Cherokee 2002-2003 4.0 Liter Gasoline Installation Instructions DOC. P/N 5000626A KIT P/N 5000543A... -
Page 2: Table Of Contents
Electrical Harness and Connections ......... 2-2 Integrating Webasto Heater Blower Control with Vehicle Blower System ....2-4 Timer Installation . -
Page 3: Foreword
General Safety Regulations and Information Any use, operation, installation, modification or application of the product not described in Webasto manuals, or The general safety regulations for the prevention of subjecting the product to extreme or unusual conditions accidents and relevant operating safety instructions must beyond the limits of specified performance characteristics is be observed at all times. - Page 4 OREWORD RAND HEROKEE In the vicinity of the coolant heater, a temperature of The operational state of the heater, i.e. an indication 85 °C (185 °F) must not be exceeded under any “on” or “off”, must be clearly visible to the operator. circumstances (e.g.
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Page 5: Heater Installation Site
Heater Installation Site The Webasto auxiliary coolant heater is to be installed on the right hand side of the engine compartment next to the engine as shown in the illustrations below. All other major components are located as shown in illustration 1. - Page 6 OREWORD RAND HEROKEE...
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Page 7: Installation
The installation instructions provided will take you step by step through the installation process. Follow all directions carefully and read all Warnings, Cautions and Notations as you work through these instructions and the installation of the BlueHeat coolant heater. CAUTION Do not deviate from the installation instructions provided in this manual. -
Page 8: Electrical Harness And Connections
NSTALLATION RAND HEROKEE Electrical Harness and Connections Fuse Block Blower To Heater (under hood Activation location) To Fuel Pump – Layout harness and familiarize yourself with harness connection points as shown in illustration 2-1. To Timer & Optional Remote To Power Source 1 - Supplemental Heat 2 - Diagnostic Connecter (Unused) - Page 9 RAND HEROKEE NSTALLATION Fuse Block Timer/Blower Harnesses – Separate timer harness, blower control harness and fuel pump harness from main heater harness. – Route timer harness, blower control harness and fuel pump harness from fuse block across top of bulkhead, behind engine towards driver side.
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Page 10: Integrating Webasto Heater Blower Control With Vehicle Blower System
– Connect the red wire from the Webasto blower control harness to the blower (motor) side of the white/pink wire of the vehicle blower control harness using the spade connectors supplied. -
Page 11: Timer Installation
RAND HEROKEE NSTALLATION Timer Installation (General Instructions) NOTE: Before installing the timer, please confirm the installation site with your customer. ATTENTION! Before drilling into any panels, ensure there are no hidden components behind the panel that may be damaged or interfere with the timer installation! –... -
Page 12: Integration Into Fuel System
NSTALLATION RAND HEROKEE Integration into Fuel System IMPORTANT! Always cut fuel line with a sharp razor knife or razor. DO NOT cut with side cutters, scissors or similar tools as doing so will cause a restriction inside the fuel line. IMPORTANT! Observe illustration 2-12 for correct fuel line connecting. - Page 13 – Connect vehicle fuel lines and electrical connections on fuel sender. – Loop webasto fuel line in the same manner as the vehicle fuel lines are at the sender unit to allow slack for servicing. Continue routing fuel line to vehicle fuel filter area.
- Page 14 – Fit P-clamp around fuel pump. Secure to vehicle using screw removed in previous step. Position as shown in Screw illustration 2-19 with connector socket pointed towards Webasto Fuel Pump front of vehicle. ATTENTION! Fuel pump must be mounted horizontally in order to operate properly and ensure correct fuel metering to the heater.
- Page 15 Fuse Block fuel pump harness as shown in illustration 2-23. – Continue along to the webasto fuse block and then down to the heater installation site. Refer to illustration 2-23. Wire Ties –...
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Page 16: Heater Installation
HEROKEE Heater Installation Front The Webasto auxiliary coolant heater is to be installed on the right hand side of the engine compartment next to the engine as shown in illustration 2-24. – Unfasten vehicle fuse box to allow removal of battery tray. - Page 17 (supplied) between heater and mounting bracket as indicated in illustration 2-27. (In later kits, the mounting bracket may already be Place 2 Spacer attached by Webasto). Washers Between Heater and Bracket 2-27: Heater Assembly - Mounting Bracket Installed –...
- Page 18 NSTALLATION RAND HEROKEE NOTE: Two different styles of hose clamps are Coolant Outlet Hose supplied in the installation kit. The wide band clamps are used on all coolant connections and the narrow band clamps will be used to attach the combustion air intake tube.
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Page 19: Exhaust System
RAND HEROKEE NSTALLATION – Place assembled heater into the installation location of Heater the vehicle as shown in illustration 2-33. Coolant Pump – Slide bracket into place under receiver/dryer mount bolt and aligning heater bracket holes with upper engine mount bracket bolt holes. –... -
Page 20: Combustion Air Intake Tube
NSTALLATION RAND HEROKEE Combustion Air Intake Tube – Route combustion air intake tube from heater up and over the front of the heater and behind the mounting bracket as shown in illustration 2-36. Combustion Air Tube Heater – Trim combustion air intake tube to length and attach air intake silencer. -
Page 21: Integration Into Coolant System
Tighten hose clamp. Refer to illustration 2-41, connection 1. – Repeat steps 3. through 5. for hose leading from Webasto heater outlet to connection point 2 as shown Front in illustration 2-41. 2-41: Coolant Hose Connections... -
Page 22: Power Connection
– Connect heater power lead to one of the main power studs located at front inside of the vehicle fuse box as Power Lead to Webasto shown in illustration 2-43. Heater System Front – Re-connect battery ground cable(s). -
Page 23: Final Inspection And Initial Start-Up
2. Set interior heater control to maximum heat position (hot) and switch off air conditioning system. 3. Start the vehicle engine and run on fast idle for 5 minutes to purge any remaining air from the Webasto heater and coolant system. While the engine is running check: •... - Page 24 NSTALLATION RAND HEROKEE Your Notes and Observations 2-18...
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Page 25: Basic Troubleshooting
Heater Lockout Reset Procedure The BlueHeat is designed with a lockout safety feature built in to the control unit. After 3 consecutive unsuccessful startup attempts, the heater will lock itself out from any further start attempts. The heater may also enter the lockout mode after experiencing an overheat condition. -
Page 26: General Malfunction Symptoms
End User service facilities. A PC Diagnostic Interface kit for the BlueHeat is available that allows for more thorough testing and troubleshooting of the heater and its components beyond the scope of this installation manual. The diagnostic kit makes it possible to read and remove (reset) stored malfunction codes from the BlueHeat memory. -
Page 27: Schematics
RAND HEROKEE CHEMATICS Schematics Wiring Schematic... -
Page 28: Plumbing Schematic
CHEMATICS RAND HEROKEE Plumbing Schematic... - Page 29 Webasto Product N.A., Inc. 3333 John Conley Drive Lapeer, MI 48446 Phone (810) 245-2400 Toll-free (800) HEATER-1 (810) 664-7720 Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org. 10/2002 Rev. 01/2003 P/N 5000626A...
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