Webasto Thermo Top E Parking Operator's manual

Water Heater
Installation documentation
Ident. No.: 1314128B_EN Fee Euro 10.00 © Webasto AG
Suzuki Splash
Petrol
from Model Year 2008
Left-hand drive vehicle
Manual air conditioning
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.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Thermo Top E Parking Heater e1
00 0003
Thermo Top C Parking Heater e1
00 0002

Suzuki Splash
1314128B_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 Splash EX e4 * 2001/116 * 0130 * ...
Engine type Engine model Output in kW Displacement in cm³
K10B Petrol 48 996
K12B Petrol 63 1242
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
Electrical system 6
Fan control 7
Remote option (Telestart) 8
Preparing installation location 9
Preparing heater 9
Installing heater 12
Combustion air 13
Exhaust gas 14
Fuel 16
Coolant circuit 20
Final Work 25
Operating Instructions for End Customer 26

Suzuki Splash
1314128B_EN 3
Heater / Installation Kit
Optional heater control either:
Heater recommended for the respective vehicle class:
The selection of the heater is based on the passenger compartment size of the vehicle and the level of
comfort required by the customer!
Foreword
This installation documentation applies to Suzuki Splash Petrol vehicles for validity, see page 2 - from
model year 2008 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" and the "operating and maintenance in-
structions" 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 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 rub protection (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
Quantity Description Order No.:
1 Suzuki-specific heater delivery scope See Suzuki price list
1 Installation kit for Suzuki Splash Petrol 1314113A
Description Order No.:
Heater controls See Suzuki price list
Vehicle Heater
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C

Suzuki Splash
1314128B_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.
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 circuit
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.

Suzuki Splash
1314128B_EN 5
Preliminary Work
WARNING!
- Open fuel tank cap, ventilate tank.
- Close the fuel tank cap again.
- Disconnect the battery "earth" or "ground" connection.
-Depressurisethe 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 intake resonator.
- Detach the wheel well trim on the right and left.
- Remove the bumper.
- Remove the fuel tank and the fuel-tank vent line according to the manufacturer's instructions.
- Remove the fuel-tank sending unit in accordance with manufacturer's instructions.
- Remove the lower cover of the instrument trim on the driver's side.
- Remove the upper A-pillar trim on the driver's side (only with Telestart).
- Remove the handbrake lever trim (only with digital timer).
Remove page 26 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater installation location
Photo shows vehicle with manual transmis-
sion!
1Heater Installa-
tion loca-
tion
1
1

Suzuki Splash
1314128B_EN 6
Electrical system
Wiring harness pass through
1Protective rubber plug
Digital timer
1Digital timer
Wiring har-
ness rout-
ing
diagram
Earth point
1Earth wire on wiring harness of heater
2Original vehicle earth point
Fuse holder, K3 relay
1Fuse holder
2Original vehicle bolt, angle bracket
3K3 relay, M5x16 bolt, washer, M5 nut
2
1
3
1
Wait until later to install the wiring har-
ness of the metering pump together
with the fuel line along the original ve-
hicle fuel lines in a 10 mm dia., 2,100
mm long corrugated tube on the under-
body
4
2
1
5
2
3
1

Suzuki Splash
1314128B_EN 7
Fan control
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-C/E GM Fan motor rt red
X1 6-pin heater connector GR Fan relay ws white
F3 25 A fuse WG Resistor group sw black
K3 Fan relay F Fuse br brown
gn green
ge yellow
XCutting point
Wiring colours may vary.
Connection to 2-pin connector 5from the fan
motor.
Produce connections as shown in wiring dia-
gram.
1Black/yellow (sw/ge) wire of fuse F
2Red (rt) wire from K3/87a
3Black (sw) wire from K3/30
4Black/yellow (sw/ge) connector
Connect-
ing fan-mo-
tor
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
Suzuki
rt
sw/
ge
sw/ws
HG
X1 4
86
85 30
87a87
K3
F3
F
GR
sw/
ge
2
1GM
M
sw
WG
6
1
5
3
4
2

Suzuki Splash
1314128B_EN 8
Remote option (Telestart)
1Receiver, M5x16 bolt,washer, flanged nut,
original vehicle hole
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor only for T100 HTM
1Fasten temperature sensor on original ve-
hicle wiring harness with cable tie
Installing
tempera-
ture sensor
1
7
1
8
1
9

1314128B_EN 9
Suzuki Splash
Preparing installation location
Bend tab 1inward at markings.
Laying on
tab
1Remove original vehicle bolt (will be re-
used)
Removing
bolt
Crossmember2onlypresentonvehicleswith
manual transmission
150 mm edge protection [2x]
Installing
edge pro-
tection
Preparing heater
Mount M6x20 bolt 2in existing hole before in-
stalling. Insert two washers between bracket
3and heater at position 4.
1Ejot screw [2x]
4Ejot screw, washer [2x]
5Hose section, 10 mm dia. clamp
Premount-
ing bracket
10
1
11
1
12
1
1 2
13
1
3
1
45
2

1314128B_EN 10
Suzuki Splash
1Exhaust pipe
a = 190
2Exhaust end section
b = 335
Discard section XPreparing
exhaust
pipe
1Loosely mount hose clamp [2x]
2Red (rt) rubber isolator [2x]
3Exhaust pipe
Preparing
exhaust
pipe
Close off condensed-water drain hole at posi-
tion 2.
1Exhaust silencer
Preparing
silencer
1Flanged nut
Installing
silencer
and ex-
haust pipe
a b
1 2
X
14
22 3
1
1
15
2
1
16
1

1314128B_EN 11
Suzuki Splash
1Combustion air pipe
a = 300
Discard section X
Cutting
combus-
tion air
pipe to
length
1Combustion air pipe
227 mm dia. hose clamp
Installing
combus-
tion air
pipe
Manual transmission:
b = 390
c = 110
d = 415
Hose Dwith long 90° elbow
Discard section X
Automatic transmission:
b = 445
c = 110
d = 415
Hose Dwith long 90° elbow
Discard section X
Cutting
coolant
hoses to
length
Push braided protection hoses onto hose B
and Dand cut to length.
Cut heat shrink plastic tubing to length.
125 mm long heat shrink plastic tubing [4x] Preparing
coolant
hoses
a
1
X
17
21
X
BD
A
X
C
B
D
1
1
1 1

1314128B_EN 12
Suzuki Splash
1Black (sw) rubber isolator
227 mm dia. hose clamp
3Hose section, 10 mm dia. clamp
Premount-
ing hose C
Installing heater
Align heater and unsure sufficient distance to
adjacent components; correct if necessary.
1Original vehicle bolt Installing
heater
1M6x25 bolt, 10 mm shim, large diameter
washer, flanged nut
Installing
heater
1M6x25 bolt, 10 mm shim, flanged nut
Installing
heater
18
2C 1
3
19
1
20
1
21
1

Suzuki Splash
1314128B_EN 13
Combustion air
1Retaining clip in existing hole
Installing
retaining
clip
Manual transmission
1Combustion air pipe
Routing
combus-
tion air
pipe
Automatic transmission
Align black (sw) rubber isolator 2to original
vehicle stud bolt 1.
3Combustion air pipe Routing
combus-
tion air
pipe
All vehicles
1Combustion air pipe
2Silencer in retaining clip
Installing
silencer
22
1
23
1
24
2
3
1
25
1 2

Suzuki Splash
1314128B_EN 14
Exhaust gas
1Exhaust end section
2Loosely mount hose clamp
3Red (rt) rubber isolator
4Slide on exhaust-gas insulation
5Red (rt) rubber isolator with groove Preparing
exhaust
end sec-
tion
Installing
exhaust
end sec-
tion
1Ejot screw
2P-clamp
Fastening
exhaust
end sec-
tion
Cut out underride protection 1.
Cuttingout
underride
protection
on left
26
3
1
4
2
5
27
28
1
2
1
29
50
45

Suzuki Splash
1314128B_EN 15
Cut out wheel well trim 1.
Cuttingout
wheel well
trim on left
1
30
80 60 20

Suzuki Splash
1314128B_EN 16
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. 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 in as shown in the wiring harness
routing diagram.
Route fuel line 2in corrugated tube 3to fire-
wall and route to vehicle underbody together
with wiring harness of metering pump.
110 mm dia. clamp
2Fuel line
310 mm dia. corrugated tube Connect-
ing heater
1Fuel-tank vent line
Discon-
necting
fuel-tank
vent line
Shorten fuel standpipe 1to 340 mm length
when stretched out and mould.
Preparing
fuel stand-
pipe
31
1 2 3
32
1
80
33
1
265
220
340

Suzuki Splash
1314128B_EN 17
116-24 mm dia. hose clamp [2x]
2Fuel-tank vent line
3Hose section, 10 mm dia. clamp
480 mm fuel-tank vent line
5Fuel standpipe Premount-
ing fuel
standpipe
Install hose section 4with 3.2 mm dia. and 8
mm dia. clamp on intake line of fuel
standpipe5.
1Fuel tank
2Original vehicle clamp (loose)
3Fuel standpipe Installing
fuel stand-
pipe
Align standpipe 1relative to bottom of fuel
tank (approx. 5 mm over bottom of fuel tank)
so that freedom of movement of feed pot and
fill level sensor is ensured.
Aligning
standpipe
in fuel tank
Install original vehicle clamp 1, install fuel-
tank sending unit and fuel tank according to
manufacturer's instructions.
Installing
fuel stand-
pipe
34
1 1
3
2
5
4
35
1 2
5
3
4
36
1
37
1

Suzuki Splash
1314128B_EN 18
Drill out perforated bracket 2to 10 mm dia. at
position 3.
1Silent block, flanged nut
Preparing
perforated
bracket
1Hose section [2x], 10 mm dia. clamp [2x]
2Rubber-coated p-clamp, metering pump,
flanged nut
3Perforated bracket
4Silent block Premount-
ing meter-
ing pump
Route fuel line and wiring harness of meter-
ing pump in corrugated tube 1along original
vehicle fuel line to fuel standpipe and secure
with cable ties.
Installing
lines
1Metering pump
2Original vehicle bolt
Installing
metering
pump
38
3
1 2
39
1 2
4
1
3
40
1
41
1
2

Suzuki Splash
1314128B_EN 19
1Hose section, 10 mm dia. clamp
2Hose section (rub protection), cable tie
[2x each]
3Hose section, 10 mm dia. clamp
4Fuel line Connect-
ing to me-
tering
pump
1Fuel line in corrugated tube
2Hose section, 10 mm dia. clamp
3Metering pump wiring harness
Connect-
ing to me-
tering
pump
42
2
3
1
4
2
43
2
3
1

Suzuki Splash
1314128B_EN 20
Coolant circuit
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 hoses, the heater must be filled with coolant.
The connection should be "inline" based on the following diagram:
Hose rout-
ing dia-
gram
All spring clips = 27 mm dia.! All hose clamps = 20-27 mm dia.!
All connecting pipes = 20x20 mm dia.
1= Black (sw) rubber isolator [2x with manual transmission, 1x with automatic transmission]!
2= Black (sw) rubber isolator , all vehicles!
A
BC
D
1
1
2