Webasto Thermo Top C Manual de usuario
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.
Water Heater unit
Installation instructions
Ident. No.: 1311556A €10 fee © Webasto AG
Dodge Caliber
Diesel
From model year 2007
For left-hand drive vehicles only
Feel the drive
Supplementary heating Thermo Top C e1
00 0002
Dodge Caliber
1311556A 2
Table of Contents
Validity
Vehicle and engine types, equipment variants as wellas national specifications, which are not listed in
these installation instructions, have not been tested. Installation according to these installation
instructions may, however, be possible.
The installation location of a time switch and summer / winter switch should be confirmed with the end
customer before installation.
Manufacturer Model Type EG-BE No. / ABE
Daimler Chrysler (USA) Dodge Caliber PK e11 * 2001 / 116 * 0142 * ...
Engine type Engine model Power in kW Engine capacity in cm³
Code: BYL Diesel 103 1968
Validity 2
Heater Unit / Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on the Document 4
Preliminary work 5
Heater unit installation location 5
Electrical Connections 6
Manual air conditioning blower control 7
Time switch 8
Summer / winter switch option 8
Remote Start Option 8
Thermo Call Option 9
Preparing the Installation Location 10
Preparing the Heater Unit 11
Installing the Heater Unit 14
Fuel Connection 15
Exhaust System 18
Water Connection 20
Final Work 22
Operating instructions for the end customer 23
Fastening Strap Template for the Metering Pump 24
Tank Extracting Device Template 25
Dodge Caliber
1311556A 3
Heater Unit / Installation Kit
Foreword
These installation instructions apply to Dodge vehicles with Caliber Diesel – validity, see page 2 – from
model year 2007 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.
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.
General Instructions
Installation should be carried out according to the general, standard rules of technology. Unless
specified otherwise, fasten hoses, lines and cable harnesses to original vehicle lines and cable
harnesses using cable clips.
Sharp edges should be fitted with edge protectors (split open plastic hose).
Spray unfinished body areas, such as bore holes, with anti-corrosion wax (Tectyl 100K, Order no.
111329).
Special Tools
- Torque spanner for 2.0 - 10 Nm
- Vice-grip wrench
- Special Chrysler tool no: 9340
Amount Description Order no.:
1 LU Thermo Top C (D) with time switch 89244D
1 LU Thermo Top C (D) with T80 remote start 9007165A
1 Installation kit for Dodge Caliber Diesel 1311554A
Special features are highlighted using the following symbols:
Mechanics
Electrics
Water connection
Fuel connection
Exhaust System
Combustion air
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
Dodge Caliber
Specific risk of injury or fatal accidents.
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.
1311556A 4
Explanatory Notes on the Document
To provide you with a quick overview of the individual working steps, you will find an identification mark
on the outside top right corner of the page in question.
Dodge Caliber
1311556A 5
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.
- Attach the duplicate label (type label) in the appropriate place.
- Remove the motor cover.
- Remove air filter and suction tube
- Remove the front left wheel-house panel
- Remove the engine underride protection.
- Remove the rear left underride protection
- Remove the rear seat bench.
- Open the left tank mounting service lid
- Remove tank mounting according to manufacturer's instructions.
- Remove the dashboard panel on the driver’s side.
- Remove the steering column panel on the driver’s side.
Remove page 23 "Operating instructions for the end customer" and insert with vehicle operating
instructions.
Heater unit installation location
1Heater unit
Installation
location
1
1
Dodge Caliber
1311556A 6
Electrical Connections
Connecting the ground wire
1Chassis ground point
2Ground wire
Installing the heater unit cable harness
1Heater unit cable harness to original vehicle
lines
Cable
harness
installation
diagram
Fuse holder, K3 relay
1Fuse holder retaining plate, bore hole
Ø 4mm, 5.5x13 self-tapping screw
2Ø 4mm bore hole, 5.5x13 self-tapping screw
3K3 relay
4Fuse holder
Cable harness feed-through
Extend the blower cable harness in the interior
with the enclosed wires of the same color!
1Blower control cable harness
2Original vehicle protective rubber sleeve
3Time switch cable harness
2
2
1
3
1
rt sw
br
bl
Don't install the metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
4
4
2
3
1
5
1
3
2
Dodge Caliber
1311556A 7
Manual air conditioning blower control
Circuit
diagram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E GM Blower motor rt red
X1 6-pin connector WG Resistor group ws white
F3 Fuse 25A F4 Blower fuse sw black
K3 Blower relay br brown
gn green
bl blue
ro pink
XSplitting point
Cable colors may vary.
Connection to 2-pin connector 2from the
blower motor.
Reconnect according to the circuit diagram.
1Blue/pink (bl/ro) wire from blower fuse
3Blue/pink (bl/ro) wire to 2 pin connector
4Black (sw) wire from relay K3/30
5Red (rt) wire to relay K3/87a
Connec-
ting the
blower
motor
Webasto
31
30
15
Dodge Caliber
HG X1
4F3
86
85 30
87a87
K3
gn/ws rt/ws F4
+
-GM
M
WG
rtrt
sw sw
br
bl/ro
bl/ro
6
1
4
3
5
2
Dodge Caliber
1311556A 8
Time switch
1Time switch
Assem-
bling the
time switch
Summer / winter switch option
1Bore hole Ø 12 mm, summer / winter
switch
Assem-
bling the
summer /
winter
switch
Remote Start Option
Position the bracket 3according to the
illustration.
1Bolt M5x16, M5 flanged nut in previously
drilled hole
2Receiver (to the right next to the steering
column)
Assem-
bling the
receiver
1Antenna
Assem-
bling the
antenna
1
7
1
8
1
2
3
9
1
10
Dodge Caliber
1311556A 9
Temperature sensor for HTM100 only
1Temperature sensor, fasten as appropriate
Assem-
bling the
temperature
sensor
Thermo Call Option
1Ø 4mm bore hole, 5.5x13 self-tapping
screws [4x each]
2Receiver (to the left next to the steering
column) Assem-
bling the
receiver
1Antenna
Assem-
bling the
antenna
1Tip switch
Assem-
bling the
tip switch
111
1
212
1
1
1
1
13
114
1311556A 10
Dodge Caliber
Preparing the Installation Location
1Rivet nut M8 in available bore hole
Inserting
rivet nuts
Loosely pre-assemble the bracket 1and with
bolt M8x30 2on the rivet nut.
3Copy the hole image
Copy the
hole image
Remove the bracket
1Ø 12.5mm bore hole, tighten M8 rivet nut
Inserting
rivet nuts
Replace metal nut with the body washer and
M6 flanged nut at position 1.
Replace
nut
15
1
16
3
1
2
17
1
18
1
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