Webasto Thermo Top C 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
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

1311556A 11
Dodge Caliber
Preparing the Heater Unit
Disassemble the circulation pump 2, the
spring band clamps 1[2x] will be used again.
Disassem-
ble the
circulation
pump
1Extension for the circulation pump cable
harness
Slide on
cable
harness
a = 350mm
b = 350mm
c = 90mm
d = 80mm
e = 620mm
Dispose of section XCutting
water
hoses into
sections
1Spring band clamp [2x], from circulation
pump
Assemble
hoseCand
D
2
119
20
1
E
X
B
b c a
CA
d
D
eXX
21
C
D 1
1

1311556A 12
Dodge Caliber
1Strut
2Loosely pre-fit ejot screw bolt
Loosely
preassem-
ble the
strutonthe
heater unit
Connect the circulation pump cable harness
and the extension with the butt connectors 4
of the same color.
1Rubberized tube clamp Ø 48mm
2Circulation pump
3M6x20 bolt, flanged nut M6 on strut Pre-
assem-
bling the
circulation
pump on
the strut
Cut
bracket to
size
Cut
bracket to
size
22
1
2
23
4
21
3
24
60mm
90mm
25
50mm
30mm
40mm
30mm

1311556A 13
Dodge Caliber
Ejot screw bolt tightening torque 10 Nm!
Insert two washers between the heater unit
and the bracket in position 2.
1Ejot screw bolt [2x]
2Ejot screw bolt, washer [2x] Pre-
assem-
bling the
bracket on
the heater
unit
1Ø 27mm hose clamps [2x]
2Connectingpipe20x20 [2x],Ø27mmhose
clamps [4x]
Pre-
assemble
the water
hose on
the heater
unit
1Spacer brackets [3x]
Inserting
spacer
bracket
1M6x20 bolt, flanged nut M6 on strut
2Combustion air pipe
3Ø 27 mm hose clamp
4Combustion air intake silencer
5Ø 52mm tube clamp Pre-
assem-
bling the
fuel pipe
26
1
2
1
27
A
E
1
1
2 2B
28
1 1 1
29
1
4
2
35

1311556A 14
Dodge Caliber
Installing the Heater Unit
Priortoassembly,putontheheater unitcable
harness
1M8x30 bolt, spring washer, washer [2x
each] on prepared rivet nuts Assem-
bling the
Heater Unit
1M6flanged nutto originalvehicle staybolts
2Strut
Assem-
bling the
Heater Unit
30
1 1
31
1
2

Dodge Caliber
1311556A 15
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.
Unless specified otherwise, always fasten using cable clips!
Fit the fuel line and cable harness with edge protectors around sharp edges.
WARNING!
The fuel line and cable harness to the metering pump should be installed based on the cable harness
installation diagram.
2Fuel line
1Hose section, Ø 10 mm hose clamps [2x]
Connectio
n to heater
1Mecanyl fuel pipe, metering pump cable
harness to original vehicle wires
Installing
lines
Note the installation position of the metering
pump 2, see the “Installation Instructions”.
The installation location is on the left before
the vehicle tank.
Drill and bend the fastening strap 4according
to the template
1Rubberized tube clamp
3Original vehicle bolt
5Silent block, flanged nut [2x]
Metering
pump
installation
location
32
21
33
1
34
1 2
4
3
5

Dodge Caliber
1311556A 16
Fuel line from the heater unit 1on the
pressuresideof the meteringpump[side with
connector].
2Hose section, Ø 10 mm hose clamps [2x].
3Metering pump cable harness, single wire
seals [2x], flat connector [2x], connector
housing
Connec-
ting to
metering
pump
Remove tank mounting according to
manufacturer's instructions.
1Tank mounting
2PositionØ16.7mmbodywasheraccording
to the illustration
3Copy the hole image, Ø 6mm bore hole Fuel take-
off
Shape, cut into sections, and insert the tank
extractingdevice 1according to the template,
see the Installation Instructions.
Inserting
tank
extracting
device
Install the tank mounting2according to the
manufacturer's instructions.
1Residual section of fuel line
3Tank extracting device
4Hose section, Ø 10 mm hose clamps [2x] Connec-
ting and
disconnect
ing the fuel
pipe
35
1 32
36
1
3
2
37
1
1
38
1
4
32

Dodge Caliber
1311556A 17
Fuel line from the tank extracting device 3on
the intake side of the metering pump 1[side
without connector].
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
2Hose section, Ø 10 mm hose clamps [2x].
Connec-
tion to
metering
pump
39
1 2
3

Dodge Caliber
1311556A 18
Exhaust System
1Exhaust pipe
a = 820mm
2Exhaust end section
b = 180mm Preparing
the
exhaust
pipe
1Angle bracket
2M6x20 bolt, M6 flanged nut on existing
hole
Assem-
bling the
angle
bracket
1Exhaust silencer
2M6x20 bolt, M6 flanged nut on bracket
Assem-
bling the
spacer nut
1Hose clamp
2Exhaust pipe
3Tubeclamp,M6x20bolt,flangednutM6on
fastening strap
4Fastening strap with holes
5M6x25 bolt, flanged nut on existing hole Assem-
bling the
exhaust
pipe
a b
1 2
1
40
2
241
1
1
5
2
42
4
3

Dodge Caliber
1311556A 19
1Exhaust pipe
2Tubeclamp,M6x20bolt,flangednutM6on
fastening strap
3Slide the rubber profile onto the exhaust
line.
4Fastening strap with holes
5M6x25 bolt, flanged nut on existing hole Assem-
bling the
exhaust
pipe
1Align rubber profile according to the
illustration
2Exhaust pipe
3Hose clamp
Assem-
bling the
exhaust
pipe
Drill Ø 42mm in the underride protection at
position 3and insert red rubber profile.
Align the exhaust end section 1flush with the
red (rt) rubber profile 3.
Assem-
bling the
exhaust
end
section
1
543
3
2
4
44
1
2
3
1
45
2
3

Dodge Caliber
1311556A 20
Water Connection
WARNING!
Tighten all hose clamps to 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!
Position hose clamps so that no other hose can be damaged!
The connection should be "inline" based on the following diagram:
Water
installation
diagram
Symbol Description Symbol Description Position Description
Connecting pipe Hose clamp 1Circulation pump
Ø 27
Ø 20x20
Ø 27
Ø 27
Ø 27Ø 27 Ø 20x20
B
1
C
D
Ø 27 Ø 27
Ø 27 Ø 27
Ø 27
Ø 27
Ø 20x20Ø 20x20
F
Ø 27 Ø 27 A
E