Webasto Thermo top evo Bedienerhandbuch

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.

The initial startup is to be executed with the Webasto Thermo Test Diagnosis.

Webasto does not accept any liability for defects and damage that are attributable to installa-

tion by untrained staff.

Water Heater

Installation documentation

Ident. No.: 1318039A_EN Fee Euro 10.00 © Webasto AG

Suzuki Jimny

Petrol

from model year 2011

Left-hand drive vehicle

Thermo Top Evo Parking Heater

00 0258

Suzuki Jimny

1318039A_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 Jimny FJ e1 * 2001 / 116 * 0056 * ...

Engine type Engine model Output in kW Displacement in cm³

M13A Petrol 63 1328

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

Preparing electrical system 6

Electrical system 7

Fan control 8

Digital timer 10

Remote option (Telestart) 10

Preparing installation location 11

Preparing heater 12

Installing bracket 13

Installing heater 14

Coolant circuit 15

Fuel 18

Exhaust gas 22

Combustion air 25

Final Work 26

Copy template of bracket hole pattern 27

Template of bracket 28

Template for fuel standpipe 29

Operating Instructions for End Customer 30

Suzuki Jimny

1318039A_EN 3

Heater / Installation Kit

Foreword

This installation documentation applies to Suzuki Jimny Petrol vehicles for validity, see page 2 - from

model year 2011 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", the "operating instructions" and the In-

stallation instructions" for the Thermo Top Evo 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. Insulate loose wires and tie back.

Sharp edges should be fitted with rub protection (split-open fuel hose).

Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).

When installing an IPCU, check or adjust the corresponding settings before installation.

Special Tools

- Torque wrench for 2.0 - 10 Nm

- Hose clamping pliers

- Metric thread-setter kit

Quantity Description Order No.:

1 Basic delivery scope Thermo Top Evo see price list

1 Installation kit for Suzuki Jimny 2011 Petrol 1318038A

1 Heater control see price list

Suzuki Jimny

1318039A_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.

Mechanical system

Electrical system

Coolant circuit

Fuel

Exhaust gas

Combustion air

Software

All dimensions are in mm!

Tightening torque of 5x13 heater bolts = 8Nm!

Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm!

Explanatory Notes on Document

You will find an identification mark on the outside top right corner of the page in question to provide you

with a quick overview of the individual working steps.

Suzuki Jimny

1318039A_EN 5

Preliminary Work

WARNING!

- Open the fuel tank cap, ventilate the tank.

- Close the fuel tank cap again.

- Disconnect the battery earth connection.

- Depressurise 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.

- Completely remove the battery.

- Remove the air filter completely.

- Remove the exhaust pipe between the middle and end silencer.

- Remove the fuel tank according to the manufacturer's instructions.

- Remove the fuel-tank sending unit in accordance with the manufacturer's instructions.

- Remove the glove compartment.

- Remove the steering column trim on the driver's side

Remove page 30 "Operating Instructions for End Customer" and add to the vehicle operating instruc-

tions.

Heater installation location

1Heater

Installa-

tion loca-

tion

Suzuki Jimny

1318039A_EN 6

Preparing electrical system

15.5 mm dia. hole

Preparing

air filter

box

16.2 mm dia. hole

Preparing

air filter

box

Produce connections as shown in wiring dia-

gram. Install fuse F4 and K1 relay will be in-

serted after installation of fuse holder.

Installing

F4, prepar-

ing K1 re-

lay

Connect wires according to wiring diagram.

1Fuse holder of passenger compartment

2Fuse F4 25A

Red (rt) wire from K1/87a

Black (sw) wire from K1/30 Connect-

ing wires

= =

85 30

87a87

gn/ws

0,75²

0,5²

4²

rt/sw

0,5²

2sw

4²

1 2

21 4

Suzuki Jimny

1318039A_EN 7

Electrical system

Positive and earth wire

1Earth wire to original vehicle earth support

point

2Positive wire on positive battery terminal

Wiring harness pass through

1Wiring harnesses of heater, heater control

2Protective rubber plug

Wiring har-

ness rout-

ing

diagram

Fuse holder of engine compartment

1M5x16 bolt, washer [2x], retaining plate of

fuse holder, nut

2Fuse F1-2

3Air filter box

Fuse holder of passenger compartment

1Fuse holder of passenger compartment

25x13 self-tapping screw

3K1 relay

Donotinstallthemeteringpump

wiring harness until later togeth-

erwith fuellinealongtheoriginal

vehicle fuel lines on the under-

body

Suzuki Jimny

1318039A_EN 8

Fan control

Wiring dia-

gram

Webasto components Vehicle components Colours and symbols

Legend

HG Heater TT Evo GS Fan switch rt red

X1 6-pin heater connector WG Resistor group sw black

X2 2-pin heater connector GM Fan motor ge yellow

X10 4-pin connector

Heater control FS Vehicle 30A fuse gn green

bl blue

K1 Fan relay ws white

F1 20A fuse br brown

F2 30A fuse

F3 1A fuse

F4 25 A fuse XCutting point

Wiring colours may vary.

Webasto

Suzuki

X2 1 2 X1

F2 F1

gn/ws

0,75²

0,5²

rt/sw

0,5² rt

4²

0,5²

X10

85 30

87a87

gn/ws

0,75²

0,5²

4²

rt/sw

0,5²

4²

rt 4²

4²

Suzuki Jimny

1318039A_EN 9

Connect same colour wires ofwiring harness

of passenger compartment fuse holder 3to

wiringharness ofheater2according towiring

diagram.

1Fuse holder of passenger compartment Connect-

ing wiring

harnesses

Connection to 2-pin connector 2[hidden]

from the fan motor.

Produce connections as shown in wiring dia-

gram.

1Green (gn) wire of fuse

3Green (gn) wire of fan motor

Red (rt) wire from K1/87a

Black (sw) wire from K1/30

Connect-

ing fan mo-

tor

1 1

Suzuki Jimny

1318039A_EN 10

Digital timer

1Digital timer

Mounting

digital tim-

Remote option (Telestart)

1M6x20 bolt, flanged nut, existing hole

2Receiver

Mounting

receiver

1Antenna

Mounting

antenna

Temperature sensor T100 HTM

Fasten temperature sensor 1with adhesive

tape.

Mounting

tempera-

ture sensor

111

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