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 warnings.
Webasto does not accept any liability for defects and damage that are attributable to
installation by untrained staff.
Water Heater Unit
Installation Instructions
Ident. No.:1312904A_EN Fee Euro 10.00 © Webasto AG
Jeep Compass
Diesel
from Model Year 2007
Left-hand drive vehicle
Feel the drive
Thermo Top C Additional Heater
e1
00 0002

Jeep Compass
1312904A_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
Daimler Chrysler (USA) Compass pk e11*2001/116*0142...
Engine type Engine model Output in kW Displacement in cm³
BSY/BYL 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
Electrical system 6
Fan controller for manual air conditioning 7
Remote option (Telestart) 8
Remote option (Thermo Call) 9
Preparing installation 10
Preparing installation location 11
Installing heater unit 13
Fuel 15
Water 18
Combustion air 22
Exhaust gas 23
Final Work 25
Operating Instructions for End Customer 26
Template for Perforated Fastening Strap 27
Template for Diesel fuel standpipe 28

Jeep Compass
1312904A_EN 3
Heater Unit/Installation Kit
Foreword
These installation instructions apply to Jeep Compass Diesel vehicles - for 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,thestipulations in the "installationinstructions"and"operating and maintenanceinstructions"
for the Thermo Top C/P/E 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
specified 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
Quantity Description Order No.:
1 LU Thermo Top C (D) with digital timer See price list
1 LU Thermo Top C (D) with Telestart See price list
1 Installation kit for Jeep Compass CRD 1312903A

Jeep Compass
1312904A_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.
Reference to general installation instructions of
Webasto components or to the manufacturer's vehicle-
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
Water
Fuel
Exhaust gas
Combustion air
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.

Jeep Compass
1312904A_EN 5
Preliminary Work
WARNING!
- Open the fuel tank cap, ventilate the 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 battery.
- Remove the engine design cover.
- Remove the entire air filter.
- Remove the lower engine cover.
- Remove the bumper.
- Remove the left wheel well trim.
- Remove the seat bench of the rear bench seat.
- Open the tank-fitting service lid on the right and left.
- Remove the fuel-tank sending unit on the right according to the manufacturer's instructions; open
the quick-release couplings inside the fuel tank.
- Remove the fuel-tanksending unit on the left accordingto the manufacturer's instructions (the fuel-
tank sending unit is installed on the left).
- Remove the lower left instrument panel trim.
- Remove the lower steering column trim.
- Remove the trim above the pedals.
- Remove the trim below the glove compartment.
Remove page 26 "Operating Instructions for End Customer" and add to the vehicle operating
instructions.
Heater unit installation location
1Heater unit
Installation
location
1
1

Jeep Compass
1312904A_EN 6
Electrical system
Power supply
1Positive battery terminal
2Ground point
Digital timer
1Summer/winter switch option
2Digital timer
Wiring
harness
installation
diagram
Fuse holder, relay K3
1Fuse holder, 4.5 mm dia. hole, 5.5x13 self-
tapping screw
2K3relay,4.5mmdia.hole;5.5x13self-tapping
screw
Wiring harness pass through
1Protective rubber plug
2
1
2
3
21
Wait until later to install the wiring
harness of the metering pump
together with the fuel line along the
original vehicle fuel lines in a
corrugated tube on the underbody
4
6
2
1
5
1
1

Jeep Compass
1312904A_EN 7
Fan controller for manual air conditioning
Wiring
diagram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C GM Fan motor rt red
X1
6-pin heater unit connector WG Resistor group ws white
F3 Fuse, 25 A F Fan fuse sw black
K3 Fan relay br brown
gn green
XCutting point
Wiring colors may vary.
Connection to 2-pin connector 3from the
blower motor.
Produce connections as shown in wiring
diagram.
1Red (rt) wire from K3/87a
2Blue/red (bl/rt) wire of fan fuse
4Blue/red (bl/rt) wire of fan motor
5Black (sw) wire from K3/30
Con-
necting
fan-motor
Webasto
31
30
15
Jeep Compass
HG X1
4F3
86
85 30
87a87
K3
gn/ws rt/ws F
+
-GM
M
WG
rtrt
sw sw
br
bl/ro
bl/ro
6
3
5 4
1 2

Jeep Compass
1312904A_EN 8
Remote option (Telestart)
1Fasten receiver with adhesive tape
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor for HTM100 only
Fasten temperature sensor 1with adhesive
tape on air duct behind instrument panel trim
(see marking). Installing
tempera-
ture sensor
1
7
1
8
1
9

Jeep Compass
1312904A_EN 9
Remote option (Thermo Call)
1Fasten receiver with adhesive tape
Installing
receiver
1Antenna
Installing
antenna
1Pushbutton
Installing
push
button
1
10
1
11
112

1312904A_EN 10
Jeep Compass
Preparing installation
A = Molded hose
b = 1030
c = 1040
Discard section XCutting
coolant
hoses to
length
Push braided protection hoses onto hose B
and C and cut to length.
Cut heat shrink plastic tubing to length.
125 mm long heat shrink plastic tubing [4x] Preparing
coolant
hoses
1Exhaust pipe
a = 210
2Exhaust end section
b = 450
Discard section XPreparing
exhaust
pipe
1Edge protection
Cutting
edge
protection
to size
A
B X C
X
X
C
B
1 1
1 1
a b
1 2
X
180180 65 75
1

1312904A_EN 11
Jeep Compass
1M6x20 bolt, pin lock
2Bracket
Preparing
bracket for
coolant
hoses
Shape 48 mm dia. rubber-coated p-clamps 1
[2x] provided as shown.
Preparing
rubber-
coated p-
clamps
Preparing installation location
1Edge protection 65
2Edge protection 180 [2x]
3Bracket Preparing
bracket
1Exhaust muffler, M6x20 bolt, flanged nut
2Bracket
Preparing
bracket
13
1
2
14
1
15
1 2
2
3
16
1
2

1312904A_EN 12
Jeep Compass
Insert two washers between heater unit and
bracket 2at position 3.
2Ejot screw [2x]
3Ejot screw, washer [2x] Preassem-
bling
heater unit
1Loosely mount original vehicle bolt [2x].
Copying
hole
pattern
Be carefully not to damage wiring harness of
heater unit when inserting!
Removeheaterunitaftercopying9.1mm dia.
hole pattern 1.
2Loosely mount M8x20 bolt, spring
lockwasher Copying
hole
pattern
19.1 mm dia. hole; M6 rivet nut
Installing
rivet nut
17
3
1 2
2
2
18
1
1
19
1
2
20
1

1312904A_EN 13
Jeep Compass
Installing heater unit
1Original vehicle bolt [2x]
Installing
bracket
Be carefully not to damage wiring harness of
heater unit when inserting!
1M6x20 bolt, spring lockwasher
2M8x20 bolt, spring lockwasher Installing
bracket
Mount 75 mm edge protection 2on battery
carrier 1.
Installing
edge
protection
Push through perforation of heater unit cover
2and insert clip-type cable tie 3.
1Wiring harness of heater unit
Mounting
wiring
harness of
heater unit
21
1
1
22
1
2
23
1
2
24
2
3
1

1312904A_EN 14
Jeep Compass
Ensure proper freedom of movement of horn
1to bracket 2.
Aligning
horn
25
1 2

Jeep Compass
1312904A_EN 15
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.
Install fuel line and metering-pump wiring harness so that they are protected against stone impact.
Unless 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 in as shown in the wiring harness
routing diagram.
1Cable tie [2x]
210 mm dia. clamp [2x]
390° molded hose
4Fuel line
Con-
nection to
heater unit
Route fuel line and wiring harness of
metering pump 1in corrugated tube 2above
original vehicle fuel line.
3Cable tie Installing
lines
Route fuel line and wiring harness of
metering pump 1above original vehicle fuel
line.
Installing
lines
26
1 2
2
3
1
4
27
3
1
3
2
33
28
1 1

Jeep Compass
1312904A_EN 16
Bend and drill perforated bracket 4in
accordance with template.
1Rubber-coated pipe clamp
2Metering pump
3Original vehicle bolt
5Silent block, flanged nut [2x] Installing
metering
pump
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
1Metering pump wiring harness
2Metering pump connector
3Hose section, 10 mm dia. clamp [2x]
4Fuel line from heater unit
Con-
necting
metering
pump
Remove fuel-tank sending unit 1in
accordance with manufacturer's
specifications.
2Lay washer with outside dia. = 17.6 mm on
bars
3Copy 6 mm dia. hole pattern Removing
fuel
Cut fuel standpipe 1to length, shape and
install, see installation instructions.
Removing
fuel
29
1 2
4
3
5
30
2
4
1
3
31
1
2
3
32
1
1

Jeep Compass
1312904A_EN 17
Install fuel-tank sending unit 1in accordance
with manufacturer's specifications.
2Fuel standpipe
3Molded hose, 10 mm dia.clamp
4Fuel line Con-
necting
fuel line
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
1Hose section, 10 mm dia. clamp [2x]
2Fuel line Con-
necting
metering
pump
33
1 2
4 3
34
1
2

Jeep Compass
1312904A_EN 18
Water
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
coolant.
The connection should be "inline" based on the following diagram:
Coolant
routing
diagram
All spring clips = 27 mm dia.! All hose clamps = 20-27 mm dia.!
All connecting pipes = 20x20 dia..
1= red (rt) rubber isolator [2x].
B
A
C
1
1

Jeep Compass
1312904A_EN 19
Pull hose off engine outlet 1; original vehicle
clamp will not be reused.
Cutting
point
Turn original vehicle clamp 1.
Con-
necting
engine
outlet
Align red (rt) rubber isolator 1relative to oil
pressure line 2.
Con-
necting
engine
outlet
Con-
necting
heater unit
35
1
A
1
36
1
AB
2
37
B

Jeep Compass
1312904A_EN 20
Con-
necting
heater unit
Align red (rt) rubber isolator 3relative to oil
pressure line 2.
1Cable tie
Routing in
engine
compart-
ment
1Hose on heat exchanger inlet
Con-
necting
heat
exchanger
inlet
1Original vehicle bolt
248 mm dia. rubber-coated p-clamp
Installing
p-clamp
38
C
39
C1 21
3
40
C 1
41
A1
B
C
2