Webasto Thermo Top C User manual

IMPORTANT!
Danger warning:
The incorrect installation or repair of Webasto heating systems may cause a fire or the
escape or fatal carbon monoxide. This may result in serious or fatal injuries.
Special company training, technical documentation, special tools and special
equipment are required for the installation and repair of Webasto heating and cooling
systems.
NEVER attempt to install or repair Webasto heating or cooling systems unless you
have completed the company training and thus acquired the required technical skills
and unless you have the technical documentation, tools and equipment available to
you that are required for completing proper installation and repair work.
ALWAYS follow all Webasto installation and repair manuals and observe all the
warnings.
Webasto cannot accept any liability for defects and damage caused by the system
being installed by untrained personnel.
Feel the drive
Suzuki Grand Vitara
Petrol
From model 2006
Left-hand drive models only
Part No. 1310500A Cover charge Euro 10.00 © Webasto AG
Water heater
Thermo Top C
Auxiliary heating system
Installation Instructions
e1
00 0002

22
Suzuki Grand Vitara
Validity
The vehicle types, engine types and equipment versions not listed in these installation instructions
have not been tested. It may nevertheless be possible to install the system using these installation
instructions.
The installation site for the digital timer and summer / winter switch should be agreed with the end
customer before installation!
Manufacturer Trade name Type EC licence no. / General operating permit
(homologation)
Suzuki Grand Vitara JB e4*2001/116*0091...
Engine type Engine type Output in kW Swept volume in cm³
J20A Petrol 103 1995
M16A Petrol 78 1586
Validity 2
Heater / installation kit 3
Foreword 3
General 3
Special tools 3
Notes on document 4
Preparations 5
Installation site for the heater 5
Electrical connections 6
Automatic air-conditioning blower control 7
Option Telestart 9
Option Thermo Call 10
Prepare installation site 11
Prepare heater 12
Install heater 13
Exhaust system 14
Integration in fuel system 16
Water connections 20
All vehicles 20
Only for 1.6 petrol 21
Only for 2.0 petrol 21
All vehicles 22
Combustion air 23
Completion 24
Operating instructions for the end customer 25
Tank connector template 26
Table of contents

33
Suzuki Grand Vitara
Heater / installation kit
optional control element as required:
additionally:
Foreword
These installation instructions apply to vehicles with Suzuki Grand Vitara with Petrol engines
(see page 2 for validity) model year 2006 and later, unless technical modifications on the vehicle
influence the installation, excluding all liability claims. Depending on the version and equipment in
the car, changes may be required to the installation work set out in these "installation instructions".
In any event, however, the directives in the "installation instructions" and "operating and servicing
instructions" for the Thermo Top C must be followed.
The appropriate engineering conventions and any instructions from the vehicle manufacturer must
be observed for the installation work.
General
Installation is carried out in accordance with general technical principles. Unless indicated otherwise in
the description, secure onto the hoses, cables and wiring harnesses using cable ties.
Fit a chafe guard over sharp edges (fuel hose cut open)!
Spray bare body parts, for example around drilled holes, with anti-corrosive wax (Tectyl 100K, order
No. 111329).
Special tools
- Torque wrench for 2.0 – 10 Nm
- Clamping claw
- Rivet nut pliers
Quantity Designation Order No.
1 Kit includes Thermo Top C petrol without digital timer 93001B
Quantity Designation Order No.
1 Digital timer 9005753C
1 Telestart T80 9007098A
Quantity Designation Order No.
1 Installation kit Suzuki Grand Vitara 1310357A

44
Special features are identified by the following symbols:
Mechanics
Electrics
Water connections
Fuel connections
Exhaust system
Combustion air
The arrow in the vehicle icon points to the position in
the vehicle and indicates the viewing direction
Suzuki Grand Vitara
Specific danger of serious or fatal accidents
Specific danger of damaging components
Specific fire and explosion hazard
Reference to general installation instructions for
Webasto components and to documents specific to the
vehicle supplied by the manufacturer
Note to a technical peculiarity
i
Notes on document
To give you a quick overview of the various procedures, you will find an identifier on the outside edge
at the top right on the appropriate page.

5
Suzuki Grand Vitara
Installation site for the heater
1Heater
Installation
position
1
1
Preparations
IMPORTANT!
- Drain the vehicle tank for removal according to the manufacturer’s instructions
- Disconnect the battery!
- Release the pressure from the cooling system!
- Transfer the factory number from the original rating plate to the duplicate rating plate
- Remove the inapplicable year number from the duplicate plate
- Fit the duplicate plate (model plate) in a suitable position where it is visible
- Completely remove the battery
- Remove the battery tray
- Remove the complete air filter and the intake hose
- Open the tank cover and vent the tank
- Close the tank cover again
- Remove the tank as instructed by the manufacturer
- Remove the tank fittings as instructed by the manufacturer
- Remove the air-conditioning control
- Remove the bottom footwell cover on the driver side (only with Thermo Call)
- Remove the bottom footwell cover on the passenger side
- Remove the A-pillar trim on the passenger side (only with Telestart and/or Thermo Call)

6
Suzuki Grand Vitara
Electrical connections
Wiring harness passage
1Rubber grommet
Digital timer
1Digital timer
Diagram
for routing
wiring
harness
Fuse holder, K3 relay
Consult circuit diagram page 8!
1Standard cable holder
5Remove cable from holder and secure with
cable tie (only 1.6 petrol), bend lug
4K3 relay, screw M5x12, washers, nut M5
3Fuse holder
2Fuse holder, screw M5x12, washers, nut M5
Optional summer/winter switch
1Summer/winter switch, hole diameter 12 mm
2
1
3
1
rt
sw
1mm²
sw
br
bl
Route the metering pump wiring
harness along the standard fuel
lines to the underbody (do this
later together with the fuel line)
i
4
5
21
4
3
5
1

7
Suzuki Grand Vitara
Automatic air-conditioning blower
control
Connection to the 2-pin plug of the blower
motor.
Make the connections using the supplied butt
connectors as shown in the circuit diagram.
1Plug 2-pin
Connection to
blower motor
Connection to the 32-pin plug G52 grey of the
air-conditioning control.
Make the connections using the supplied butt
connectors as shown in the circuit diagram.
1Plug G52 grey
2Standard violet/red cable insulated
3Cable black 1 mm² F4 Connection
air-condition-
ing control
1Plug G52 pin1
Plug air-
conditioning
control
6
1
7
1
3
2
1

8
Suzuki Grand Vitara
Circuit
diagram of
automatic
air
condition-
ing system
Webasto components Components Suzuki Colours and symbols
Key
HG Heater TT-C/E GM Blower motor rt red
F3 Fuse GR Blower relay ws white
K3 Blower relay F19 Fuse sw black
F4 Fuse 10A F40 Fuse br brown
KB Air-conditioning control gn green
G52 Plug 32-pin bl blue
vi violet
Insulate ends of cables
and secure out of the way
XCut
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
Suzuki Grand Vitara
rt
F3
4
HG
X1
F4 10A
sw
sw
K3
87a8786
85 30
bl/ws
M
+
-
GM
F19 F40
KB
1
St G52
rt/sw
GR
vi/rt
vi/rt
!
i

9
Suzuki Grand Vitara
Option Telestart
2Fan housing
1Receiver, Velcro tape (self-adhesive)
To install
receiver
1Aerial
To install
aerial
Temperature sensor (only HTM 100)
1Temperature sensor
2Velcro tape (self-adhesive)
3Air shaft
Temperature
sensor
HTM 100
1
2
8
i
1
9
1
10
23

10
Suzuki Grand Vitara
Option Thermo Call
1Receiver, Velcro tape (self-adhesive 2x)
To install
receiver
1Aerial
To install
aerial
1Button
To install
button
111
i
1
12
1
13

11
Suzuki Grand Vitara
Prepare installation site
1Existing hole, rivet nut M6
To pull in
rivet nut
Install holder, align, transfer hole pattern!
1Holder
2Screw M6x20, spring ring
3Hole pattern, hole diameter 9.1 mm
To transfer
hole pattern
1Rivet nut M6
To pull in
rivet nut
Install holder, transfer hole pattern, check
distance to sensor!
1Holder
4Screw M6x20, spring ring
5Screw M6x20, spring ring
3Hole pattern holder
2Drill the hole with a diameter of 7 mm To install
holder,
transfer hole
pattern
14
1
15
2
1
3
16
1
17
3
21
5
4

12
Suzuki Grand Vitara
1Holder
2Screw M6x20, body washer, spring ring,
spacer nut M6x40
To install
holder
1Holder
2Screw M6x60, spring ring, spacer 40 mm
To install
holder
Prepare heater
Ejot screws, tightening torque 10 Nm!
1Ejot stud bolts
To prepare
heater
18
2
1
19
1 2
20
1

13
Suzuki Grand Vitara
Install heater
Connect the plug to the heater, spray
protective wax onto the plug!
1Clip cable tie in preperforated hole
2Wiring harness heater
Installation
of heater
Align heater!
Ejot screws, tightening torque 10 Nm!
Insert two washers at position x between the
heater and holder!
1Holder
2Ejot stud bolts, collar nut M6 [2x]
3Ejot stud bolts, collar nut M6 Installation
of heater
1Cable tie
2Wiring harness heater
Installation
of heater
21
1
2
22
X 1
32
23
1
2

14
Suzuki Grand Vitara
Exhaust system
1Exhaust line
a = 520 mm
2Exhaust end section
b = 120 mm
Dispose of section XTo prepare
exhaust line
1Existing hole, pull in rivet nut M6
2Existing threaded insert M6
To prepare
installation
site
Ensure adequate distance!
4Heater
2Exhaust line
1Red rubber section
3Hose clip
To install
exhaust line,
align rubber
section
Ensure adequate distance!
1Threaded insert M6, bracket, body washer,
spring ring, screw M6x20
3Exhaust line
2Pipe clip, screw M6x20, collar nut M6
To install
exhaust line
and end
section
a b
1 2
X
24
2
1
1 2 43
25
1
2
3
26

15
Suzuki Grand Vitara
5Exhaust line
1Hose clip
3Rivet nut M6
2Exhaust silencer, spacer 30 mm,
screw M6x50, spring ring
4Exhaust line end section, hose clip
To install
silencer
Ensure adequate distance!
1Exhaust line end section
To align
exhaust line
end section
27
5
1
3
4
2
28
1

16
Suzuki Grand Vitara
Integration in fuel system
WARNING!
Open the car’s filler cap, vent the tank and close the filler cap again!
Catch escaping fuel using a suitable container!
Lay the fuel line and metering pump wiring harness so that they are protected from stones!
Unless indicated otherwise in the description, secure using cable ties!
Fit a chafe guard on the fuel line and wiring harness around sharp edges!
IMPORTANT!
The fuel line and wiring harness for the metering pump are installed according to the wiring harness
routing diagram.
Remove and dismantle the tank fitting as
instructed by the manufacturer!
Drill the hole with a diameter of 6 mm in the
centre according to the figure.
2Tank fitting
1Existing embossing
To prepare
tank fitting
Shape and cut the tank connector to length in
accordance with the template and insert it,
see "installation instructions"!
1Tank connector
2Tank fitting
To insert
tank
connector
1Tank fitting
2Tank connector
To insert
tank
connector
29
1
2
30
1
2
i
31
1
2
i

17
Suzuki Grand Vitara
Install the tank fittings as instructed by the
manufacturer!
1Tank fitting
2Tank connector
3Hose section,
hose clips diameter 10 mm [2x]
4Fuel line
To connect
fuel line
Install the fuel line without chafing!
2Fuel line
1Cable ties [4x]
Line routing
Install the fuel line without chafing!
1Fuel line
3Hose section (chafe guard)
2Cable ties [2x]
Install the tank as instructed by the
manufacturer
Line routing
Check the installation position of the metering
pump, see "installation instructions"!
3Drill the hole with a diameter of 6.5 mm
2Metering pump
1Rubberised clip, anti-vibration mount,
collar nut M6 [2x]
Installation
of metering
pump
32
4
1 2 3
i
33
1 1
2
1 1
34
3
1
2
2
35
2
1
3
i

18
Suzuki Grand Vitara
Fuel line from the tank connector to the intake
side of the metering pump (side without plug).
Check the position of the components and
correct if necessary. Ensure that all moving
parts can move easily.
Install the fuel line without taking up too much
space!
2Fuel line cut to length, cable tie
3Metering pump
1Hose section,
hose clip 10 mm [2x]
Connection
to metering
pump
Install the fuel line without taking up too much
space!
1Hose section,
hose clip 10 mm [2x]
2Fuel line
3Hose section (chafe guard)
Connection
at heater
Position the fuel line and metering pump
wiring harness and secure with cable ties!
Install the fuel line without taking up too much
space!
1Fuel line, metering pump wiring harness
2Fuel line, metering pump wiring harness in
heat protection hose
Positioning
of fuel line in
engine
compart-
ment
Route the heat protection line along the
standard lines to the underbody, checking the
distance to the exhaust system!
Secure with cable ties!
1Fuel line, metering pump wiring harness in
heat protection hose Positioning
of fuel line
in engine
compart-
ment
36
1
3
2
37
1
2
3
38
2
1 1 1
2
1
39
1

19
Suzuki Grand Vitara
Install the fuel line and metering pump wiring
harness without taking up too much space,
secure to standard lines with cable ties!
1Fuel line, metering pump wiring harness
Line routing
Fuel line from the heater to the discharge side
of the metering pump (side with plug).
1Fuel line
2Wiring harness metering pump, plug
metering pump
3Shaped hose,
hose clip 10 mm [2x]
4Cable tie Connection
to metering
pump
40
1
41
2 31 4
i

20
Suzuki Grand Vitara
Water connections
IMPORTANT!
Tighten all hose clips with a torque of 2.0 + 0.5 Nm!
Catch escaping coolant water using a suitable container!
Install the water hoses with no kinks! Unless indicated otherwise in the description, secure using cable
ties. Position hose clamps and spring strip clip so that no other hose can be damaged!
Carry out "inline" integration according to the following diagram:
All vehicles
Water
routing
diagram
Connection pipes with 1.6 l petrol Ø 15x20!
Connection pipes with 2.0 l petrol Ø 17x20!
Heat
exchanger
Engine
Ø 27
Ø 27
Ø 27
Ø27 Ø24
Ø 24
A
B