Webasto Thermo Top Evo Installation Documentation
Parking heater for suzuki jimny petrol from model year 2011
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Also See for Thermo Top Evo:
- Installation documentation (64 pages) ,
- Manual (57 pages) ,
- Workshop manual (52 pages)
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Water Heater
Thermo Top Evo Parking Heater
Installation documentation
Suzuki Jimny
Petrol
from model year 2011
Left-hand drive vehicle
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, specialised tools and equipment are
required to install and repair Webasto heating and cooling systems.
Only original Webasto parts must be used. For this, also see the catalog of air and water heat-
er accessories from Webasto.
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 tech-
nical 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.
The initial startup is to be executed with the Webasto Thermo Test Diagnosis.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Ident. No.: 1318039A_EN
e1
00 0258
Fee Euro 10.00
Feel the drive
© Webasto AG
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Table of Contents
Related Manuals for Webasto Thermo Top Evo
Summary of Contents for Webasto Thermo Top Evo
- Page 1 Specialist company training, technical documentation, specialised tools and equipment are required to install and repair Webasto heating and cooling systems. Only original Webasto parts must be used. For this, also see the catalog of air and water heat- er accessories from Webasto.
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Page 2: Table Of Contents
Suzuki Jimny Table of Contents Validity Preparing installation location Heater / Installation Kit Preparing heater Foreword Installing bracket General Instructions Installing heater Special Tools Coolant circuit Explanatory Notes on Document Fuel Preliminary Work Exhaust gas Heater installation location Combustion air Preparing electrical system Final Work Electrical system... -
Page 3: Heater / Installation Kit
However, the stipulations in this "installation documentation", the "operating instructions" and the In- stallation instructions" for the Thermo Top Evo must always 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 Document
Suzuki Jimny Explanatory Notes on Document You will find an identification mark on the outside top right corner of the page in question to provide you with a quick overview of the individual working steps. Mechanical system Electrical system Coolant circuit Fuel Exhaust gas Combustion air... -
Page 5: Preliminary Work
Suzuki Jimny Preliminary Work WARNING! - Open the fuel tank cap, ventilate the tank. - Close the fuel tank cap again. - Disconnect the battery earth connection. - Depressurise 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
Suzuki Jimny Preparing electrical system 1 5.5 mm dia. hole Preparing air filter 1 6.2 mm dia. hole Preparing air filter Produce connections as shown in wiring dia- gram. Install fuse F4 and K1 relay will be in- rt/sw gn/ws serted after installation of fuse holder. -
Page 7: Electrical System
Suzuki Jimny Electrical system Positive and earth wire Wiring harness pass through 1 Earth wire to original vehicle earth support 1 Wiring harnesses of heater, heater control point 2 Protective rubber plug 2 Positive wire on positive battery terminal Wiring har- ness rout- diagram Do not install the metering pump... -
Page 8: Fan Control
0,75² 0,5² 4² rt/sw gn/ws 0,5² 4² 0,75² 0,5² 4² 0,5² 0,5² Webasto components Vehicle components Colours and symbols Heater TT Evo Fan switch 6-pin heater connector WG Resistor group black 2-pin heater connector GM Fan motor yellow 4-pin connector... - Page 9 Suzuki Jimny Connect same colour wires of wiring harness of passenger compartment fuse holder 3 to wiring harness of heater 2 according to wiring diagram. 1 Fuse holder of passenger compartment Connect- ing wiring harnesses Connection to 2-pin connector 2 [hidden] from the fan motor.
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Page 10: Digital Timer
Suzuki Jimny Digital timer 1 Digital timer Mounting digital tim- Remote option (Telestart) 1 M6x20 bolt, flanged nut, existing hole 2 Receiver Mounting receiver 1 Antenna Mounting antenna Temperature sensor T100 HTM Fasten temperature sensor 1 with adhesive tape. Mounting tempera- ture sensor 1318039A_EN... -
Page 11: Preparing Installation Location
Suzuki Jimny Preparing installation location Cut out insulation mat 1 at the markings. Cutting out insulation 1 Template of hole pattern in bracket 2 Copy hole pattern [4x] Copying hole pat- tern When drilling hole watch the components at the rear 1 9.1 mm dia. -
Page 12: Preparing Heater
Suzuki Jimny Preparing heater 1 Perforated bracket Bending perforated bracket 35° 1 Circulating pump mounting 2 Perforated bracket angled down 3 M6x25 bolt, flanged nut Preparing mounting of circulat- ing pump Discard section X Hose B = 180°, 18 mm dia. moulded hose Cutting hoses to length... -
Page 13: Installing Bracket
Suzuki Jimny 1 90° connecting pipe 2 Circulating pump Mounting hoses Installing bracket Cut bracket to length and bend according to template. 1 M6x20 bolt, spring lockwasher [3x each] Mounting 2 Bracket part A bracket 3 Bracket part B 1 M6x20 bolt, spring lockwasher 2 Circulating pump mounting premounted Mounting circulating... -
Page 14: Installing Heater
Suzuki Jimny Installing heater 1 5x13 self-tapping bolt [2x] 2 Heater Mounting heater 1 5x13 self-tapping bolt [2x] Mounting heater Insert circulating pump 3 into circulating pump mounting 2 . 1 Mount wiring harness of circulating pump [2x] 4 Insert wiring harness of heater [2x] Mounting circulating pump... -
Page 15: Coolant Circuit
Suzuki Jimny Coolant circuit WARNING! Any coolant running off should be collected using an appropriate container. Route hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. The heater must be filled with coolant when mounting the hoses. The connection should be "inline"... - Page 16 Suzuki Jimny 1 14x18 mm connecting pipe Preparing hoses 1 Hose section of heat exchanger inlet 2 Engine outlet hose section 3 Discard hose section Cutting point 1 Engine outlet hose section Connect- ing engine outlet 1 Circulating pump Connect- ing circu- lating pump...
- Page 17 Suzuki Jimny 1 Hose section of heat exchanger inlet Connect- ing heat exchanger inlet Ensure sufficient distance from neighbouring components. 1 4x20 hose bracket 2 8x22 hose bracket Routing 1318039A_EN...
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Page 18: Fuel
Suzuki Jimny 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. Route 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 19 Suzuki Jimny 1 Fuel line and wiring harness of metering pump in corrugated tube Routing lines 1 Metering pump 2 Original vehicle bolt, angle bracket 3 M6x25 bolt, flanged nut 4 Metering pump mounting Mounting metering pump 1 Hose section, 10 mm dia. clamp [2x] 2 Wiring harness of metering pump, con- nector installed 3 Fuel line and wiring harness of metering...
- Page 20 Suzuki Jimny 1 Drill out 2.0 mm dia. hole to 6.0 mm dia. Fuel ex- traction Shape fuel standpipe 1 according to tem- plate, cut to length and install. 2 Fuel-tank sending unit Installing fuel stand- pipe 1 Fuel standpipe 2 Sealing nut Installing fuel stand-...
- Page 21 Suzuki Jimny Install fuel-tank sending unit 3 in accordance with manufacturer's instructions. 1 Fuel tank 2 90° moulded hose with 3.5 mm dia. on fuel standpipe Connect- 4 Fuel line ing fuel 5 10 mm dia. clamp line 6 9 mm dia. clamp Check the position of the components;...
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Page 22: Exhaust Gas
Suzuki Jimny Exhaust gas Discard section X 1 Exhaust pipe a = 880 Preparing exhaust 2 Exhaust end section pipe b = 60 1 7.0 mm dia. hole Copying hole pat- tern 1 Perforated bracket Bending perforated bracket 70° 70° 1 Silencer 2 M6x16 bolt, spring lockwasher, perforat- ed bracket... - Page 23 Suzuki Jimny 1 Perforated bracket Bending perforated bracket 90° 45° 1 Perforated bracket angled down 2 Brake line bracket 3 Original vehicle bolt Mounting perforated bracket 1 Bracket of vacuum line 2 M6x30 spacer nut on original vehicle stud bolt 3 Silent block, flanged nut 4 Perforated bracket Mounting...
- Page 24 Suzuki Jimny Ensure freedom of movement of A/C wire 2 and all neighbouring components. (min. 20 mm) 1 Exhaust pipe Mounting exhaust pipe Ensure freedom of movement of all neigh- bouring components. (min. 20 mm) 1 Brake line bracket 2 Exhaust pipe 3 Perforated bracket Mounting 4 M6x20 bolt, p-clamp, flanged nut...
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Page 25: Combustion Air
Suzuki Jimny Combustion air 1 Combustion air pipe 2 Retaining clip in hole 3 Silencer Mounting silencer 1 Combustion air pipe 2 25 mm dia. clamp Mounting combus- tion air pipe 1318039A_EN... -
Page 26: Final Work
- Place "Switch off parking heater before refilling" signboard in the area of the filler neck - For initial start up and function check, see installation instructions Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78... -
Page 27: Copy Template Of Bracket Hole Pattern
Suzuki Jimny Copy template of bracket hole pattern Ø 7mm Ø 7mm 100mm Ø 7mm Ø 7mm Ø 7mm Scale 1:1 Compare the size of the printed version with dimension lines. Permitted toler- ance a maximum of 2%. Set the printer settings to “no margin” or “minimise margins”... -
Page 28: Template Of Bracket
Suzuki Jimny Template of bracket Ø 7mm Ø 7mm 60° Ø 7mm 100 mm Scale 1:1 Compare the size of the printed version with dimension lines. Permitted toler- ance a maximum of 2%. Set the printer settings to “no margin” or “minimise margins”... -
Page 29: Template For Fuel Standpipe
Suzuki Jimny Template for fuel standpipe 100mm Scale 1:1 Compare the size of the printed version with dimension lines. Permitted toler- ance a maximum of 2%. Set the printer settings to “no margin” or “minimise margins” and 100% of the 100mm normal size. -
Page 30: Operating Instructions For End Customer
Suzuki Jimny 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.