Webasto thermo top evo Operator's manual

Feel the drive
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.
Water Heater
Installation documentation
Ident. No.: 1318039A_EN Fee Euro 10.00 © Webasto AG
Suzuki Jimny
Petrol
from model year 2011
Left-hand drive vehicle
Thermo Top Evo Parking Heater
e1
00 0258

Suzuki Jimny
1318039A_EN 2
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in this installation
documentationhavenot beentested. However,installationaccordingtothis installationdocumentation
may be possible.
The installation location of the digital timer should be confirmed with the end customer before installa-
tion.
Manufacturer Model Type EG BE No. / ABE
Suzuki Jimny FJ e1 * 2001 / 116 * 0056 * ...
Engine type Engine model Output in kW Displacement in cm³
M13A Petrol 63 1328
Validity 2
Heater / Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater installation location 5
Preparing electrical system 6
Electrical system 7
Fan control 8
Digital timer 10
Remote option (Telestart) 10
Preparing installation location 11
Preparing heater 12
Installing bracket 13
Installing heater 14
Coolant circuit 15
Fuel 18
Exhaust gas 22
Combustion air 25
Final Work 26
Copy template of bracket hole pattern 27
Template of bracket 28
Template for fuel standpipe 29
Operating Instructions for End Customer 30

Suzuki Jimny
1318039A_EN 3
Heater / Installation Kit
Foreword
This installation documentation applies to Suzuki Jimny Petrol vehicles for validity, see page 2 - from
model year 2011 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 the installation documentation.
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.
General Instructions
Installation should be carried out according to the general, standard rules of technology. Unless spec-
ified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses
using cable ties. Insulate loose wires and tie back.
Sharp edges should be fitted with rub protection (split-open fuel hose).
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).
When installing an IPCU, check or adjust the corresponding settings before installation.
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Metric thread-setter kit
Quantity Description Order No.:
1 Basic delivery scope Thermo Top Evo see price list
1 Installation kit for Suzuki Jimny 2011 Petrol 1318038A
1 Heater control see price list

Suzuki Jimny
1318039A_EN 4
Special features are highlighted using the following symbols:
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
Specific risk of injury or fatal accidents.
Specific risk of damage to components.
Specific risk of fire or explosion.
Referenceto generalinstallationinstructions ofWebas-
tocomponentsortothemanufacturer'svehicle-specific
documents.
Reference to a special technical feature.
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
Software
All dimensions are in mm!
Tightening torque of 5x13 heater bolts = 8Nm!
Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm!
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.

Suzuki Jimny
1318039A_EN 5
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.
- Attach the duplicate label (type label) in the appropriate place.
- Completely remove the battery.
- Remove the air filter completely.
- Remove the exhaust pipe between the middle and end silencer.
- Remove the fuel tank according to the manufacturer's instructions.
- Remove the fuel-tank sending unit in accordance with the manufacturer's instructions.
- Remove the glove compartment.
- Remove the steering column trim on the driver's side
Remove page 30 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater installation location
1Heater
Installa-
tion loca-
tion
1
1

Suzuki Jimny
1318039A_EN 6
Preparing electrical system
15.5 mm dia. hole
Preparing
air filter
box
16.2 mm dia. hole
Preparing
air filter
box
Produce connections as shown in wiring dia-
gram. Install fuse F4 and K1 relay will be in-
serted after installation of fuse holder.
Installing
F4, prepar-
ing K1 re-
lay
Connect wires according to wiring diagram.
1Fuse holder of passenger compartment
2Fuse F4 25A
Red (rt) wire from K1/87a
Black (sw) wire from K1/30 Connect-
ing wires
2
15
35
1
3
20
= =
1
86
85 30
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
4²
rt/sw
0,5²
F3
1
2sw
4²
rt
4²
1 2
21 4
1
2

Suzuki Jimny
1318039A_EN 7
Electrical system
Positive and earth wire
1Earth wire to original vehicle earth support
point
2Positive wire on positive battery terminal
Wiring harness pass through
1Wiring harnesses of heater, heater control
2Protective rubber plug
Wiring har-
ness rout-
ing
diagram
Fuse holder of engine compartment
1M5x16 bolt, washer [2x], retaining plate of
fuse holder, nut
2Fuse F1-2
3Air filter box
Fuse holder of passenger compartment
1Fuse holder of passenger compartment
25x13 self-tapping screw
3K1 relay
5
1
2
6
21
Donotinstallthemeteringpump
wiring harness until later togeth-
erwith fuellinealongtheoriginal
vehicle fuel lines on the under-
body
7
3
2
1
8
2
3
1

Suzuki Jimny
1318039A_EN 8
Fan control
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT Evo GS Fan switch rt red
X1 6-pin heater connector WG Resistor group sw black
X2 2-pin heater connector GM Fan motor ge yellow
X10 4-pin connector
Heater control FS Vehicle 30A fuse gn green
bl blue
K1 Fan relay ws white
F1 20A fuse br brown
F2 30A fuse
F3 1A fuse
F4 25 A fuse XCutting point
Wiring colours may vary.
Webasto
31
30
15
Suzuki
HG
X2 1 2 X1
52
F2 F1
gn/ws
0,75²
ge
0,5²
rt/sw
0,5² rt
4²
br
0,5²
X10
86
85 30
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
4²
rt/sw
0,5²
F3
br
0,5²
WG
GS
+
-
GM
M
FS
1
2
4²
sw
4²
rt 4²
gn
4²
bl
4²
gn

Suzuki Jimny
1318039A_EN 9
Connect same colour wires ofwiring harness
of passenger compartment fuse holder 3to
wiringharness ofheater2according towiring
diagram.
1Fuse holder of passenger compartment Connect-
ing wiring
harnesses
Connection to 2-pin connector 2[hidden]
from the fan motor.
Produce connections as shown in wiring dia-
gram.
1Green (gn) wire of fuse
3Green (gn) wire of fan motor
Red (rt) wire from K1/87a
Black (sw) wire from K1/30
Connect-
ing fan mo-
tor
9
1
3
2
10
3
2
1 1
2
1
2

Suzuki Jimny
1318039A_EN 10
Digital timer
1Digital timer
Mounting
digital tim-
er
Remote option (Telestart)
1M6x20 bolt, flanged nut, existing hole
2Receiver
Mounting
receiver
1Antenna
Mounting
antenna
Temperature sensor T100 HTM
Fasten temperature sensor 1with adhesive
tape.
Mounting
tempera-
ture sensor
111
2
1
12
1
13
1
14

1318039A_EN 11
Suzuki Jimny
Preparing installation location
Cut out insulation mat 1at the markings.
Cuttingout
insulation
mat
1Template of hole pattern in bracket
2Copy hole pattern [4x]
Copying
hole pat-
tern
When drilling hole watch the components at
the rear
19.1 mm dia. hole, rivet nut [4x each]
Installing
rivet nut
15
1
16
2
1
2
2
2
17
1
1
1
1

1318039A_EN 12
Suzuki Jimny
Preparing heater
1Perforated bracket
Bending
perforated
bracket
1Circulating pump mounting
2Perforated bracket angled down
3M6x25 bolt, flanged nut
Preparing
mounting
of circulat-
ing pump
Discard section X
Hose B= 180°, 18 mm dia. moulded hose
A=100
C=75
D=60
E=370 Cutting
hoses to
length
1Water connection piece, sealing ring [2x
each]
25x15 self-tapping bolt, retaining plate of
water connection pieces
Mounting
water con-
nection
pieces
35°
80
1
18
2
1
3
ACX
D
B
E
19
1
1
2

1318039A_EN 13
Suzuki Jimny
190° connecting pipe
2Circulating pump
Mounting
hoses
Installing bracket
Cut bracket to length and bend according to
template.
1M6x20 bolt, spring lockwasher [3x each]
2Bracket part A
3Bracket part B
Mounting
bracket
1M6x20 bolt, spring lockwasher
2Circulating pump mounting premounted
Mounting
circulating
pump
mount
2
D
E
C
20
1
1
21
1
1
3 2
1
22
2

1318039A_EN 14
Suzuki Jimny
Installing heater
15x13 self-tapping bolt [2x]
2Heater
Mounting
heater
15x13 self-tapping bolt [2x]
Mounting
heater
Insert circulating pump 3into circulating
pump mounting 2.
1 Mount wiring harness of circulating pump [2x]
4Insert wiring harness of heater [2x] Mounting
circulating
pump
23
2
1
1
24
1
1
25
1
3
1
2
44

Suzuki Jimny
1318039A_EN 15
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" based on the following diagram:
Hose rout-
ing dia-
gram
All connecting spring clips not designated = 25 mm dia.
All connecting pipes without a specific designation and = 18x18 mm dia.
Ø 18x14
Ø 18x14
A
B
C
D
E
Ø 22
Ø 22

Suzuki Jimny
1318039A_EN 16
114x18 mm connecting pipe
Preparing
hoses
1Hose section of heat exchanger inlet
2Engine outlet hose section
3Discard hose section
Cutting
point
1Engine outlet hose section
Connect-
ing engine
outlet
1Circulating pump
Connect-
ing circu-
lating
pump
A 1
B26
27
1 2
3
28
A
B
1
29
B
1

Suzuki Jimny
1318039A_EN 17
1Hose section of heat exchanger inlet
Connect-
ing heat
exchanger
inlet
Ensure sufficient distance from neighbouring
components.
14x20 hose bracket
28x22 hose bracket Routing
30
E
1
A
31
21 E

Suzuki Jimny
1318039A_EN 18
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.
Mount the fuel line and wiring harness with rub protection on sharp edges.
WARNING!
The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness rout-
ing diagram.
Complete connector of metering pump after
routing. Pin assignment is irrelevant.
1Connector housing
2Lock
3Blue/brown (bl / br) wires
4Coding
5Timer lock
Remove
connector
1Shorten 180° moulded hose
Preparing
hose
1Fuel line and wiring harness of metering
pump in 10 mm dia. corrugated tube
2Shorten 180° moulded hose
10 mm dia. clamp [2x]
Connect-
ing heater
32
1 43
5
5
2
33
1
10
34
2
1

Suzuki Jimny
1318039A_EN 19
1Fuel line and wiring harness of metering
pump in corrugated tube
Routing
lines
1Metering pump
2Original vehicle bolt, angle bracket
3M6x25 bolt, flanged nut
4Metering pump mounting
Mounting
metering
pump
1Hose section, 10 mm dia. clamp [2x]
2Wiring harness of metering pump, con-
nector installed
3Fuel line and wiring harness of metering
pump in corrugated tube Connect-
ing meter-
ing pump
Remove and dismantle fuel-tank sending unit 1
in accordance with manufacturer's instructions.
2M5 nut, copy hole pattern,
2.0 mm dia. hole Fuel ex-
traction
35
1 1 1
36
3
1 2
4
37
1
2
3
38
1
2

Suzuki Jimny
1318039A_EN 20
1Drill out 2.0 mm dia. hole to 6.0 mm dia.
Fuel ex-
traction
Shape fuel standpipe 1according to tem-
plate, cut to length and install.
2Fuel-tank sending unit
Installing
fuel stand-
pipe
1Fuel standpipe
2Sealing nut
Installing
fuel stand-
pipe
Shorten 90° moulded hose 1at the side with
3.5 mm dia..
Preparing
hose
39
1
40
1 2
1
41
2
1
42
1
10