Webasto Thermo Top C Installation Instructions Manual
For suzuki grand vitara left-hand drive models only
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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
Thermo Top C
Auxiliary heating system
Installation Instructions
Suzuki Grand Vitara
Petrol
From model 2006
Left-hand drive models only
IMPORTANT!
Danger warning:
The incorrect installation or repair of Webasto heating systems may cause a fire or the
escape or fatal carbon monoxide. This may result in serious or fatal injuries.
Special company training, technical documentation, special tools and special
equipment are required for the installation and repair of Webasto heating and cooling
systems.
NEVER attempt to install or repair Webasto heating or cooling systems unless you
have completed the company training and thus acquired the required technical skills
and unless you have the technical documentation, tools and equipment available to
you that are required for completing proper installation and repair work.
ALWAYS follow all Webasto installation and repair manuals and observe all the
warnings.
Webasto cannot accept any liability for defects and damage caused by the system
being installed by untrained personnel.
Part No. 1310500A
e1
00 0002
Cover charge Euro 10.00
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
IMPORTANT! Danger warning: The incorrect installation or repair of Webasto heating systems may cause a fire or the escape or fatal carbon monoxide. This may result in serious or fatal injuries. Special company training, technical documentation, special tools and special equipment are required for the installation and repair of Webasto heating and cooling systems. -
Page 2: Table Of Contents
Suzuki Grand Vitara Table of contents Validity Prepare heater Heater / installation kit Install heater Foreword Exhaust system General Integration in fuel system Special tools Water connections Notes on document All vehicles Preparations Only for 1.6 petrol Installation site for the heater Only for 2.0 petrol Electrical connections All vehicles... -
Page 3: Heater / Installation Kit
Suzuki Grand Vitara Heater / installation kit Quantity Designation Order No. Kit includes Thermo Top C petrol without digital timer 93001B optional control element as required: Quantity Designation Order No. Digital timer 9005753C Telestart T80 9007098A additionally: Quantity Designation Order No. -
Page 4: Notes On Document
Specific danger of damaging components Specific fire and explosion hazard Reference to general installation instructions for Webasto components and to documents specific to the vehicle supplied by the manufacturer Note to a technical peculiarity The arrow in the vehicle icon points to the position in... -
Page 5: Preparations
Suzuki Grand Vitara Preparations IMPORTANT! - Drain the vehicle tank for removal according to the manufacturer’s instructions - Disconnect the battery! - Release the pressure from the cooling system! - Transfer the factory number from the original rating plate to the duplicate rating plate - Remove the inapplicable year number from the duplicate plate - Fit the duplicate plate (model plate) in a suitable position where it is visible - Completely remove the battery... -
Page 6: Electrical Connections
Suzuki Grand Vitara Electrical connections Wiring harness passage Digital timer 1 Rubber grommet 1 Digital timer Route the metering pump wiring harness along the standard fuel lines to the underbody (do this 1mm² later together with the fuel line) Diagram for routing wiring harness... -
Page 7: Automatic Air-Conditioning Blower Control
Suzuki Grand Vitara Automatic air-conditioning blower control Connection to the 2-pin plug of the blower motor. Make the connections using the supplied butt connectors as shown in the circuit diagram. Connection to 1 Plug 2-pin blower motor Connection to the 32-pin plug G52 grey of the air-conditioning control. - Page 8 Suzuki Grand Vitara vi/rt rt/ws Circuit diagram of automatic condition- ing system bl/ws vi/rt rt/sw St G52 F4 10A Webasto components Components Suzuki Colours and symbols Heater TT-C/E Blower motor Fuse Blower relay white Blower relay Fuse black Fuse 10A Fuse...
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Page 9: Option Telestart
Suzuki Grand Vitara Option Telestart 2 Fan housing 1 Receiver, Velcro tape (self-adhesive) To install receiver 1 Aerial To install aerial Temperature sensor (only HTM 100) 1 Temperature sensor 2 Velcro tape (self-adhesive) 3 Air shaft Temperature sensor HTM 100... -
Page 10: Option Thermo Call
Suzuki Grand Vitara Option Thermo Call 1 Receiver, Velcro tape (self-adhesive 2x) To install receiver 1 Aerial To install aerial 1 Button To install button... -
Page 11: Prepare Installation Site
Suzuki Grand Vitara Prepare installation site 1 Existing hole, rivet nut M6 To pull in rivet nut Install holder, align, transfer hole pattern! 1 Holder 2 Screw M6x20, spring ring 3 Hole pattern, hole diameter 9.1 mm To transfer hole pattern 1 Rivet nut M6 To pull in rivet nut... -
Page 12: Prepare Heater
Suzuki Grand Vitara 1 Holder 2 Screw M6x20, body washer, spring ring, spacer nut M6x40 To install holder 1 Holder 2 Screw M6x60, spring ring, spacer 40 mm To install holder Prepare heater Ejot screws, tightening torque 10 Nm! 1 Ejot stud bolts To prepare heater... -
Page 13: Install Heater
Suzuki Grand Vitara Install heater Connect the plug to the heater, spray protective wax onto the plug! 1 Clip cable tie in preperforated hole 2 Wiring harness heater Installation of heater Align heater! Ejot screws, tightening torque 10 Nm! Insert two washers at position x between the heater and holder! 1 Holder 2 Ejot stud bolts, collar nut M6 [2x]... -
Page 14: Exhaust System
Suzuki Grand Vitara Exhaust system 1 Exhaust line a = 520 mm 2 Exhaust end section b = 120 mm To prepare Dispose of section X exhaust line 1 Existing hole, pull in rivet nut M6 2 Existing threaded insert M6 To prepare installation site... - Page 15 Suzuki Grand Vitara 5 Exhaust line 1 Hose clip 3 Rivet nut M6 2 Exhaust silencer, spacer 30 mm, screw M6x50, spring ring 4 Exhaust line end section, hose clip To install silencer Ensure adequate distance! 1 Exhaust line end section To align exhaust line end section...
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Page 16: Integration In Fuel System
Suzuki Grand Vitara Integration in fuel system WARNING! Open the car’s filler cap, vent the tank and close the filler cap again! Catch escaping fuel using a suitable container! Lay the fuel line and metering pump wiring harness so that they are protected from stones! Unless indicated otherwise in the description, secure using cable ties! Fit a chafe guard on the fuel line and wiring harness around sharp edges! IMPORTANT! - Page 17 Suzuki Grand Vitara Install the tank fittings as instructed by the manufacturer! 1 Tank fitting 2 Tank connector 3 Hose section, hose clips diameter 10 mm [2x] 4 Fuel line To connect fuel line Install the fuel line without chafing! 2 Fuel line 1 Cable ties [4x] Line routing...
- Page 18 Suzuki Grand Vitara Fuel line from the tank connector to the intake side of the metering pump (side without plug). Check the position of the components and correct if necessary. Ensure that all moving parts can move easily. Install the fuel line without taking up too much space! Connection to metering...
- Page 19 Suzuki Grand Vitara Install the fuel line and metering pump wiring harness without taking up too much space, secure to standard lines with cable ties! 1 Fuel line, metering pump wiring harness Line routing Fuel line from the heater to the discharge side of the metering pump (side with plug).
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Page 20: Water Connections
Suzuki Grand Vitara Water connections IMPORTANT! Tighten all hose clips with a torque of 2.0 + 0.5 Nm! Catch escaping coolant water using a suitable container! Install the water hoses with no kinks! Unless indicated otherwise in the description, secure using cable ties. -
Page 21: Only For 1.6 Petrol
Suzuki Grand Vitara a = 570 mm b = 640 mm Dispose of section X To cut water hoses to length Cut woven protection hoses in half and push onto hose A and B To prepare water hoses Only for 1.6 petrol 1 Hose section heat exchanger input 2 Hose section engine output 3 Remove hose holder... -
Page 22: All Vehicles
Suzuki Grand Vitara All vehicles 1 Cable tie Connection at heater 1 Cable tie 2 Hose holder Positioning in engine compartment Fill the water hoses with cooling water before connecting! 1 Hose section heat exchanger input rotated 2 Hose engine output 3 Cable tie Connection at engine... -
Page 23: Combustion Air
Suzuki Grand Vitara Combustion air 1 Combustion air line a = 300 mm Dispose of section X To cut com- bustion air line to length 6 Heater 1 Combustion air intake line, hose clip diameter 27 mm 5 Hole diameter 6.2 mm 3 Retaining clip 4 Intake silencer 2 Cable tie... -
Page 24: Completion
B-pillar on the left Feel the drive Webasto AG Postfach 80 - 82132 Stockdorf - Hotline 0 18 05 / 93 22 78 Hotfax (0395) 55 92-353 - http://www.webasto.de Printed in Germany 08/05 Printed by: Steffen... -
Page 25: Operating Instructions For The End Customer
Suzuki Grand Vitara Operating instructions for the end customer Please remove this page and insert it into the owner’s manual for the vehicle! Make the following settings before you shut down the car: 1 Temperature set to "28 max." 2 Air vent to windscreen 3 Blower to max. -
Page 26: Tank Connector Template
Suzuki Grand Vitara Tank connector template 100 mm Scale 1:1 Compare the size of the hard copy with the dimension lines. Maximum tolerance 2%. If the tolerance is larger than this correct the printer settings or request an original print. 100 mm...