Table of Contents
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Water Heater Unit
Thermo Top E Auxiliary
Heating
Thermo Top C Auxiliary
Heating
Thermo Top P Auxiliary
Heating
Installation Instructions
Suzuki Grand Vitara
Diesel
From model year 2006
Valid for vehicle frame no.: JSAJTD44...
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. 1310833A
e1
00 0003
e1
00 0002
e1
00 0104
€10 fee
Feel the drive
© Webasto AG
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Table of Contents
Related Manuals for Webasto Suzuki Grand Vitara
Summary of Contents for Webasto Suzuki Grand Vitara
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Page 1: Installation Instructions
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. -
Page 2: Table Of Contents
Suzuki Grand Vitara Table of Contents Validity Preparing the Installation Location Heater Unit / Scope of Delivery Preparing the Heater Unit Foreword Installing the Heater Unit General Instructions Water Connection Special Tools Fuel Connection Explanatory Notes on the Document Exhaust System... -
Page 3: Heater Unit / Scope Of Delivery
Foreword These installation instructions apply to vehicles Suzuki Grand Vitara with Diesel engines. – Re. validity, see page 2 – from model year 2006 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. Depending on the vehicle version and equipment, modifications may be necessary during installation with respect to these installation instructions. -
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
Suzuki Grand Vitara Preliminary Work WARNING! - Disconnect the battery. - Let off 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: Preparing The Electronics
Suzuki Grand Vitara Preparing the Electronics sw 1,0mm² Cutting wire into 2900 sections Connect according to the circuit diagram. Pull the wire section 2 into the enclosed insulation hose and, later, in the passenger gn/ws compartment. Preparing fuse F4... -
Page 7: Electrical Connections
Suzuki Grand Vitara Electrical Connections Positive and ground connection Cable harness feed-through 1 Ground wire to the original vehicle chassis 1 Protective rubber sleeve ground point 2 Blower controller cable harness, time switch 2 Positive wire to battery positive terminal... -
Page 8: Automatic Air Conditioning Blower Control
Suzuki Grand Vitara Automatic air conditioning blower control Connection to 2-pin connector 1 from the blower motor. Connect with enclosed butt connectors according to the circuit diagram. Connect- ing the 2 Blue/white (bl/ws) wire from blower relay blower 4 Red (rt) wire from K3/87a... - Page 9 Suzuki Grand Vitara Webasto Suzuki Grand Vitara vi/rt rt/ws Automatic condition- ing circuit diagram bl/ws vi/rt rt/sw Webasto components Suzuki components Colors and symbols Heater unit TT-C/E Blower motor 6-pin heater unit Blower relay white connector Fuse Air conditioning control...
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Page 10: Time Switch
Suzuki Grand Vitara Time switch 1 Time switch Assem- bling the time switch Summer / winter switch option 1 Summer / winter switch, bore hole Ø12 mm Assem- bling the summer / winter switch Remote Start Option 2 Fan housing... -
Page 11: Thermo Call Option
Suzuki Grand Vitara Temperature gauge (only for HTM 100) 1 Temperature gauge 2 Velcro tape (self adhesive) 3 Air duct Assem- bling the tempera- ture gauge Thermo Call Option 1 Receiver, Velcro tape (self adhesive 2x) Assemblin g the receiver... -
Page 12: Preparing The Installation Location
Suzuki Grand Vitara Preparing the Installation Location Run the heater unit cable harness 2 to position 1 , make loop, run back to the heater unit installation location. Run the metering pump cable 3 to the metering pump installation location. -
Page 13: Preparing The Heater Unit
Suzuki Grand Vitara Preparing the Heater Unit Enclosed hose 30° Ø 20mm Enclosed molded hose 180° Ø 20mm b = 975mm c = 780mm Cutting water hose Dispose of sections X into Cut off hose C just after the bend... -
Page 14: Installing The Heater Unit
Suzuki Grand Vitara Installing the Heater Unit Before assembling the heater unit, lower the crossarm 3 and replace the original vehicle bolt at position 4 with an M6x30 bolt. 1 Spacer with recess 8 mm Loosely 2 Spacer with recess 5mm, body washer assem- 5 Ø... -
Page 15: Water Connection
Suzuki Grand Vitara Water Connection WARNING! Tighten all hose clamps with 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. - Page 16 Suzuki Grand Vitara Remove the original vehicle hose 1 from the motor outlet to the heat exchanger inlet and dispose. The spring band clamps will be used again. Splitting point Ensure sufficient distance from adjacent components. 1 Bore hole Ø 9.1mm, M6 rivet nut, M6x20 bolt, spring washer 2 Rubberized tube clamp Ø...
- Page 17 Suzuki Grand Vitara Check the entire length of the water hoses and correct if necessary. Fasten the water hose B to the cable harness with cable ties 1 . Installing in the engine compart- ment...
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Page 18: Fuel Connection
Suzuki Grand Vitara 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. - Page 19 Suzuki Grand Vitara Separate the leading fuel line 1 according to the figure and insert the fuel extractor. 2 Separation location, fuel extractor, Ø 10 mm hose clamps [2x]. Fuel take- 1 Hose section, Ø 10 mm hose clamps [2x].
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Page 20: Exhaust System
Suzuki Grand Vitara Exhaust System 1 Exhaust pipe a = 560mm 2 Exhaust end section b = 90mm Preparing Dispose of section X exhaust pipe 1 Silencer 2 20mm spacer 3 M6x40 bolt, body washer, M6 flanged nut on existing hole... -
Page 21: Final Work
2 M6x30 bolt, body washer, 10 mm spacer Assem- bling the underride protection 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 06/06Printed by: Steffen... -
Page 22: Operating Instructions For The End Customer
Suzuki Grand Vitara Operating instructions for the end customer Please remove page and add to the vehicle operating instructions. WARNING! The installation of the auxiliary heating on the underbody compromises the wading and off-road capabilities of the vehicle. Avoid major mechanical effects on the underbody (for example, scraping bottom)! The vehicle may not drop below the lower edge of the vehicle body.