Webasto Dodge Journey (JC) User manual

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 suc-
cessfully 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 warnings.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Water Heater Unit
Installation Instructions
Ident. No.:1314082A_EN Fee Euro 10.00 © Webasto AG
Dodge Journey (JC)
Gasoline and Diesel
from Model Year 2009
Left-hand drive vehicle
Manual air conditioning
Feel the drive
Thermo Top C Additional Heater
e1
00 0002
Thermo Top P Additional Heater e1
00 0104

Dodge Journey (JC)
1314082A_EN 2
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However,installation according to these installationinstructions may
be possible.
The installation location of a digital timer and summer/winter switch should be confirmed with the end
customer before installation.
Manufacturer Model Type EG-BE No./ABE
Chrysler (USA) Dodge Journey JC e1 1* 2001/116 * 0145 * ...
Engine type Engine model Output in kW Displacement in cm³
B Gasoline 125 2360
BWD Diesel 103 1968
Validity 2
Heater Unit/Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater unit installation location 5
Preparing electrical system 6
Electrical system 7
Fan controller 8
Remote option (Telestart) 9
Remote option (Thermo Call) 10
Preparing installation location 11
Installing heater unit 12
Coolant 14
Gasoline 23
Diesel 18
Fuel 22
Gasoline 23
Diesel 18
Combustion air 26
Exhaust gas 27
Final Work 28
Template for Gasoline Fuel Standpipe 29
Template for Diesel fuel standpipe 30
Operating Instructions for End Customer 31

Dodge Journey (JC)
1314082A_EN 3
Heater Unit/Installation Kit
Heater unit recommended for the respective vehicle class:
The selection of the heater unit is based on the passenger compartment size of the vehicle and the
level of comfort required by the customer!
Foreword
These installation instructions apply to Dodge Journey (JC) Gasoline and Diesel vehicles - for validity,
see page 2 - from model year 2009 and later, assuming technical modifications to the vehicle do not
affect installation, any liability claims excluded. Depending on the vehicle version and equipment, mod-
ifications may be necessary during installation with respect to these installation instructions.
However,thestipulations in the "installationinstructions"and"operating and maintenanceinstructions"
for the Thermo Top C/P 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.
Sharp edges should be fitted with edge protectors (split-open plastic hose).
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K,
Order No. 111329).
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Metric thread-setter kit
- Chrysler Special Tool for Fuel-Tank Sending Unit
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for Dodge Journey (JC) Gasoline and Diesel 1314072A
Vehicle Heater Unit
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

Dodge Journey (JC)
1314082A_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.
ReferencetogeneralinstallationinstructionsofWebas-
tocomponentsortothemanufacturer'svehicle-specific
documents.
Reference to a special technical feature.
All dimensions are in mm!
Tightening torque of hose clamps = 2.0 + 0.5 Nm!
Tightening torque of Ejot screws, Ejot studs = 10 Nm!
Mechanical system
Electrical system
Coolant
Fuel
Exhaust gas
Combustion air
Software
Explanatory Notes on 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 Journey (JC)
1314082A_EN 5
Preliminary Work
WARNING!
- Open fuel tank cap, ventilate tank.
- Close the tank cap again.
- Disconnect the battery "earth" or "ground" connection.
-Depressurizethe 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 engine cover.
- Detach the servo reservoir.
- Detach the coolant expansion tank.
- Detach the fuse and relay box in the engine compartment.
- Detach and remove the right and left-hand wheel well trim.
- Remove the bumper.
- Remove the underride protection.
- Remove the fuel tank in accordance with the manufacturer's instructions (empty if necessary).
- Remove the lower instrument panel trim in the driver's side footwell.
- Remove the trim below the steering wheel.
Remove page 31 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater unit installation location
1Heater unit
Installa-
tion loca-
tion
11

Dodge Journey (JC)
1314082A_EN 6
Preparing electrical system
1Bracket of fuse and relay box
25.5 mm dia. hole
Hole for
angle
bracket
1M5x16 bolt, washer, flanged nut
2Fuse holder
3K3 relay
4Retaining plate for fuse holder
5Fuses pushed on Premount
wiring har-
ness
2
1
10
10
2
1 2
3
4
5

Dodge Journey (JC)
1314082A_EN 7
Electrical system
Positive and ground connection
1
Positive wire on original vehicle positive support point
2Ground wire on original vehicle ground sup-
port point
Digital timer and summer/winter switch op-
tion
1Summer/winter switch, drilled hole 12 mm dia.
2Digital timer
Wiring har-
ness in-
stallation
diagram
Fuse holder, relay K3
1Angle bracket
2M5x16 bolt, washers, M5 flanged nut
Wiring harness pass through
1
Wiring harness of fan controller and digital timer
2Protective rubber plug
3
1
2
4
2
1
Do not install themetering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
5
2
1
6
1
2

Dodge Journey (JC)
1314082A_EN 8
Fan controller
Wiring dia-
gram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E GM Fan motor rt red
X1
6-pin heater unit connector WG Resistor group bl blue
F3 25 A fuse GS Fan switch sw black
K3 Fan relay VSVM Power supply module
C114 57-pin connector
XCutting point
Wiring colors may vary.
Connector C114 1disconnected (on contact
side)!
2Socket 30
Connector
C114
Webasto
31
30
15
Dodge
F3
86
85 30
87a87
K3
HG
X1 4
GS WG
+
-
GM M
4²
bl
rt
sw
4²
4²
4²
bl
VSVM C114
30
7
1
2

Dodge Journey (JC)
1314082A_EN 9
Connection on 57-pin connector C114 2in
driver's side footwell.
Produce connections as shown in wiring dia-
gram.
1Blue (bl) wire connector C114/30
3Red (rt) wire from K3/87a
4Black (sw) wire from K3/30
5Blue (bl) wire of fan motor
Connect-
ing fan-mo-
tor
Remote option (Telestart)
Fasten receiver 1with adhesive tape.
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor for HTM100 only
Fasten temperature sensor 1with adhesive
tape.
Installing
tempera-
ture sensor
8
1
3
4
2
5
19
1
10
1
11

Dodge Journey (JC)
1314082A_EN 10
Remote option (Thermo Call)
Fasten receiver 1with adhesive tape.
Installing
receiver
1Antenna
Installing
antenna
1Push button
Installing
push but-
ton
1
12
1
13
114

1314082A_EN 11
Dodge Journey (JC)
Preparing installation location
Remove original vehicle bolts at
position 1[2x] and discard.
Removing
bolts
Drill out bracket 2to 9.5 mm dia. at
position 1[2x].
Preparing
bracket
Copy hole pattern to battery tray at
position 3[2x] on frame side member.
1M8x70 bolt, 40 mm shim
2Bracket
4M8x70 bolt, 40 mm shim, 5 mm shim Loosely
mount
bracket
Remove bracket.
19.1 mm dia. hole; mount rivet nut [2x each]
Installing
rivet nut
15
1
1
16
1 2
1
17
1 2
4
3
3
18
1
1

1314082A_EN 12
Dodge Journey (JC)
1M8x70 bolt, spring lockwasher, 40 mm
shim
2M6x70 bolt, spring lockwasher, 40 mm
shim, 5 mm shim [2x each]
3M8x70 bolt, spring lockwasher, 40 mm
shim, 5 mm shim Installing
bracket
Glue on a foam strip in area of marking at po-
sition 1. Cut 120 mm off edge protection 2
and mount.
Preassem-
bling
bracket on
heater unit
Installing heater unit
Loosely route wiring harness of heater unit 1
(will be fastened later with fuel line).
Routing
wiring har-
ness
Mount connector before installing heater unit.
1Wiring harness of heater unit
Routing
wiring har-
ness
19
1 2
3 2
20
2
1
21
1
1
1
22
1

1314082A_EN 13
Dodge Journey (JC)
Insert two washers between heater unit and
bracket 2at Position 1.
1Ejot screw, washer [2x]
3Ejot screw Installing
heater unit
1Ejot screw
2Ejot stud
Installing
heater unit
23
3
1 2
24
2
1

Dodge Journey (JC)
1314082A_EN 14
Coolant
WARNING!
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 ties. Position clamps so that no
other hose can be damaged! When installing the coolant hose, the heater unit must be filled with cool-
ant.
The connection should be "inline" based on the following diagram:
Coolant
routing di-
agram
Connecting pipe . All hose clamps = 20-27 mm dia.
1= Original vehicle spring clip !
A
B
C
1
Ø 20x18
Ø 20x17

Dodge Journey (JC)
1314082A_EN 15
Gasoline
a = 1300
b = 1440
Hose C= 90° elbow, 18x18
Discard section XCutting
coolant
hoses to
length
Push braided protection hoses onto hose A
and Band cut to length.
Cut heat shrink plastic tubing to length.
150 mm long heat shrink plastic tubing [6x] Preparing
coolant
hoses
Cut 40 mm off second foam strip and glue
onto original vehicle bolt 1. Cut open fabric
protective hose 2and fasten on brake line
with cable tie.
Installing
rub protec-
tion
Remove original vehicle nut at position 1and
discard.
1Original vehicle stud bolt, M6x30 spacer
nut
285 mm foam strip Installing
spacer nut
AX
B
X
X
C
A
B
1 1
1 1
1
1
25
2
1
26
1
2

Dodge Journey (JC)
1314082A_EN 16
1Original vehicle stud bolt, M6x40 spacer
nut
Installing
spacer nut
Connect-
ing heater
unit outlet
Connect-
ing heater
unit inlet
Glue on adhesive base 1, secure hoses A
and Bwith cable tie
Routing in
engine
compart-
ment
27
1
28
b
29
a
30
1
b
a

Dodge Journey (JC)
1314082A_EN 17
1Spacer nut, M6x20 bolt, spring lockwasher
248 mm dia. rubber-coated p-clamp
Routing in
engine
compart-
ment
1Spacer nut, M6x20 bolt, spring lockwasher
248 mm dia. rubber-coated p-clamp
Routing in
engine
compart-
ment
Disconnect hose to engine outlet/heat ex-
changer inlet 2at connection piece on heat
exchanger inlet. Spring clip 1will be reused.
Cutting
point
Connect-
ing heat
exchanger
inlet
31
b
2
a
1
32
b
a
1
2
33
2
1
34
b
C

Dodge Journey (JC)
1314082A_EN 18
Ensure sufficient distance to neighboring
components.
1Hose of engine outlet
2Original vehicle spring clip Connect-
ing engine
outlet
Diesel
a = 1400
b = 1440
Hose C= 90° elbow, 18x18
Discard section X
Cutting
coolant
hoses to
length
Push braided protection hoses onto hose A
and Band cut to length.
Cut heat shrink plastic tubing to length.
150 mm long heat shrink plastic tubing [6x] Preparing
coolant
hoses
Cut 30 mm off second foam strip 1and glue
onto original vehicle bolt. Cut open fabric pro-
tective hose 2and fasten on brake line with
cable tie.
Installing
rub protec-
tion
35
12a
AX
B
X
X
C
A
B
1 1
1 1
1
1
36
2
1

Dodge Journey (JC)
1314082A_EN 19
Remove original vehicle nut at position 1and
discard.
1Original vehicle stud bolt, M6x30 spacer
nut
285 mm foam strip Installing
spacer nut
Remove original vehicle nut at position 1and
discard.
1Original vehicle stud bolt, M6x40 spacer
nut
2Heat guard plate detached Installing
spacer nut
Connect-
ing heater
unit outlet
Connect-
ing heater
unit inlet
37
1
2
38
1
2
39
b
40
a

Dodge Journey (JC)
1314082A_EN 20
Routing in
engine
compart-
ment
1Spacer nut, M6x20 bolt, spring lockwasher
248 mm dia. rubber-coated p-clamp
Routing in
engine
compart-
ment
1Spacernut,M6x20bolt,springlockwasher,
48 mm dia. rubber-coated p-clamp, heat
guard plate
Routing in
engine
compart-
ment
Disconnect hose to engine outlet/heat ex-
changer inlet 2at connection piece on heat
exchanger inlet. Spring clip 1will be reused.
Cutting
point
41
a
b
42
b
a
1
2
43
1
44
1
2