Webasto Thermo Top C Installation Instructions Manual
Dodge 2007 caliber
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Also See for Thermo Top C:
- Installation instructions manual (56 pages) ,
- Operating and installation instructions (39 pages) ,
- Operating and maintenance instructions (4 pages)
Table of Contents
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Water Heater unit
Supplementary heating Thermo Top C
Installation instructions
Dodge Caliber
Diesel
From model year 2007
For left-hand drive vehicles only
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 warning
instructions.
Webasto does not accept any liability for defects and damage that are attributable to an
installation by untrained staff.
Ident. No.: 1311556A
e1
00 0002
€10 fee
Feel the drive
© Webasto AG
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Table of Contents
Related Manuals for Webasto Thermo Top C
Summary of Contents for Webasto Thermo Top C
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Page 1: Installation Instructions
For left-hand drive vehicles only 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 Caliber Table of Contents Validity Preparing the Installation Location Heater Unit / Installation Kit Preparing the Heater Unit Foreword Installing the Heater Unit General Instructions Fuel Connection Special Tools Exhaust System Explanatory Notes on the Document Water Connection Preliminary work Final Work Heater unit installation location Operating instructions for the end customer 23... -
Page 3: Heater Unit / Installation Kit
However, where this is the case the stipulations in the "installation instructions" and "operating and maintenance instructions" for the Thermo Top C should be observed. The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work. -
Page 4: Explanatory Notes On The Document
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. The arrow in the vehicle icon indicates the position on the vehicle and the angle. -
Page 5: Preliminary Work
Dodge Caliber Preliminary work WARNING! - Open the tank cap, ventilate the tank. - Close the tank cap again. - Disconnect the battery. - Pressure in 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: Electrical Connections
Dodge Caliber Electrical Connections Connecting the ground wire Installing the heater unit cable harness 1 Chassis ground point 1 Heater unit cable harness to original vehicle 2 Ground wire lines Don't install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the Cable... -
Page 7: Manual Air Conditioning Blower Control
Dodge Caliber Manual air conditioning blower control Webasto Dodge Caliber Circuit diagram gn/ws rt/ws bl/ro bl/ro Webasto components Vehicle components Colors and symbols Heater unit TT-C/E Blower motor 6-pin connector Resistor group white Fuse 25A Blower fuse black Blower relay... -
Page 8: Time Switch
Dodge Caliber Time switch 1 Time switch Assem- bling the time switch Summer / winter switch option 1 Bore hole Ø 12 mm, summer / winter switch Assem- bling the summer / winter switch Remote Start Option Position the bracket 3 according to the illustration. -
Page 9: Thermo Call Option
Dodge Caliber Temperature sensor for HTM100 only 1 Temperature sensor, fasten as appropriate Assem- bling the temperature sensor Thermo Call Option 1 Ø 4mm bore hole, 5.5x13 self-tapping screws [4x each] 2 Receiver (to the left next to the steering column) Assem- bling the... -
Page 10: Preparing The Installation Location
Dodge Caliber Preparing the Installation Location 1 Rivet nut M8 in available bore hole Inserting rivet nuts Loosely pre-assemble the bracket 1 and with bolt M8x30 2 on the rivet nut. 3 Copy the hole image Copy the hole image Remove the bracket 1 Ø... -
Page 11: Preparing The Heater Unit
Dodge Caliber Preparing the Heater Unit Disassemble the circulation pump 2 , the spring band clamps 1 [2x] will be used again. Disassem- ble the circulation pump 1 Extension for the circulation pump cable harness Slide on cable harness a = 350mm b = 350mm c = 90mm d = 80mm... - Page 12 Dodge Caliber 1 Strut 2 Loosely pre-fit ejot screw bolt Loosely preassem- ble the strut on the heater unit Connect the circulation pump cable harness and the extension with the butt connectors 4 of the same color. 1 Rubberized tube clamp Ø 48mm 2 Circulation pump Pre- 3 M6x20 bolt, flanged nut M6 on strut...
- Page 13 Dodge Caliber Ejot screw bolt tightening torque 10 Nm! Insert two washers between the heater unit and the bracket in position 2 . 1 Ejot screw bolt [2x] 2 Ejot screw bolt, washer [2x] Pre- assem- bling the bracket on the heater unit 1 Ø...
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Page 14: Installing The Heater Unit
Dodge Caliber Installing the Heater Unit Prior to assembly, put on the heater unit cable harness 1 M8x30 bolt, spring washer, washer [2x Assem- each] on prepared rivet nuts bling the Heater Unit 1 M6 flanged nut to original vehicle stay bolts 2 Strut Assem- bling the... -
Page 15: Fuel Connection
Dodge Caliber Fuel Connection CAUTION! Open the vehicle's tank-cap lock, 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 cable harness so that they are protected against stone impact. Unless specified otherwise, always fasten using cable clips! Fit the fuel line and cable harness with edge protectors around sharp edges. - Page 16 Dodge Caliber Fuel line from the heater unit 1 on the pressure side of the metering pump [side with connector]. 2 Hose section, Ø 10 mm hose clamps [2x]. 3 Metering pump cable harness, single wire Connec- seals [2x], flat connector [2x], connector ting to housing metering...
- Page 17 Dodge Caliber Fuel line from the tank extracting device 3 on the intake side of the metering pump 1 [side without connector]. Check the position of the components; adjust if necessary. Check that they have free clearance. Connec- tion to 2 Hose section, Ø...
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Page 18: Exhaust System
Dodge Caliber Exhaust System 1 Exhaust pipe a = 820mm 2 Exhaust end section b = 180mm Preparing exhaust pipe 1 Angle bracket 2 M6x20 bolt, M6 flanged nut on existing hole Assem- bling the angle bracket 1 Exhaust silencer 2 M6x20 bolt, M6 flanged nut on bracket Assem- bling the... - Page 19 Dodge Caliber 1 Exhaust pipe 2 Tube clamp, M6x20 bolt, flanged nut M6 on fastening strap 3 Slide the rubber profile onto the exhaust line. 4 Fastening strap with holes Assem- 5 M6x25 bolt, flanged nut on existing hole bling the exhaust pipe 1 Align rubber profile according to the...
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Page 20: Water Connection
Dodge Caliber Water Connection WARNING! Tighten all hose clamps to 2.0 + 0.5 Nm. 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 clips! Position hose clamps so that no other hose can be damaged! The connection should be "inline"... - Page 21 Dodge Caliber Disconnect engine outlet hose 2 from heat exchanger inlet supports. Dispose of spring band clamp 1 . Splitting point 1 Connect engine outlet hose section with hose A Connec- ting engine outlet Connect hose F (enclosed 180° bend) with hose E and connect to the heat exchanger inlet connecting piece.
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Page 22: Final Work
2 M6 flanged nut on bolt M6x25 Assem- bling the underride protection Feel the drive Webasto AG PO Box 80 - 82132 Stockdorf Hotline 01805 / 932278 - Hotfax 0395 / 5592-353 http://www.webasto.de Printed in Germany 02/2007 Printed by: Steffen... -
Page 23: Operating Instructions For The End Customer
Dodge Caliber Operating instructions for the end customer Please remove page and add to the vehicle operating instructions. Note: We recommend adjusting the heating time to the driving time heating time = driving time Example: For a driving time of 20 minutes (one way) we recommend not exceeding 20 minutes of power on time. It the summer / winter switch option is installed for the heater unit, switch this according to the season. -
Page 24: Fastening Strap Template For The Metering Pump
Dodge Caliber Fastening Strap Template for the Metering Pump Ø 10.5mm Torsion line 90° 100mm 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”... -
Page 25: Tank Extracting Device Template
Dodge Caliber Tank Extracting Device Template 100mm 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. 100mm 1311556A...