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Webasto BlueHeat Installation instructions manual

Manual is about: Jeep 2002 Grand Cherokee; Jeep 2003 Grand Cherokee

Summary of BlueHeat

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    Jeep grand cherokee 2002-2003 4.0 liter gasoline installation instructions blueheat coolant heater doc. P/n 5000626a kit p/n 5000543a.

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    T able of c ontents b lue h eat - j eep g rand c herokee ii table of contents 1. Foreword 1.1 scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 meaning of warnings, cautions and notes . . . . . . . . . . . . . . . . . ...

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    B lue h eat - j eep g rand c herokee 1 f oreword 1-1 1. Foreword 1.1 scope and purpose these non-binding installation instructions are intended to support authorized webasto trained distributors, dealers and personnel in the installation of the thermo top series coolant heater. Webasto product north...

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    1 f oreword b lue h eat - j eep g rand c herokee 1-2 in the vicinity of the coolant heater, a temperature of 85 °c (185 °f) must not be exceeded under any circumstances (e.G. During body paint work). A violation of this temperature limit may cause permanent damage to the electronics. When checking t...

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    B lue h eat - j eep g rand c herokee 1 f oreword 1-3 1.5 heater installation site the webasto auxiliary coolant heater is to be installed on the right hand side of the engine compartment next to the engine as shown in the illustrations below. All other major components are located as shown in illust...

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    1 f oreword b lue h eat - j eep g rand c herokee 1-4.

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    B lue h eat - j eep g rand c herokee 2 i nstallation 2-1 2.2 preparations heater kit 1. Verify and identify all contents of kit. Vehicle 1. Verify fuel content in tank. Important! For safety reasons due to weight of fuel and tank, it is recommended there be no more than ¼ tank or less of fuel presen...

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    2 i nstallation b lue h eat - j eep g rand c herokee 2-2 2.3 electrical harness and connections – layout harness and familiarize yourself with harness connection points as shown in illustration 2-1. – locate ground splice (brown wires attached to metal plate) and attach to ground stud located under ...

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    B lue h eat - j eep g rand c herokee 2 i nstallation 2-3 – separate timer harness, blower control harness and fuel pump harness from main heater harness. – route timer harness, blower control harness and fuel pump harness from fuse block across top of bulkhead, behind engine towards driver side. – l...

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    2 i nstallation b lue h eat - j eep g rand c herokee 2-4 – route the timer and blower control harnesses over the steering column. Route the blower control harness to the center console area as shown in illustration 2-7. – temporarily route the webasto blower motor control harness through the ash tra...

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    B lue h eat - j eep g rand c herokee 2 i nstallation 2-5 2-11: timer placement (example only) 2.5 timer installation (general instructions) note: before installing the timer, please confirm the installation site with your customer. Attention! Before drilling into any panels, ensure there are no hidd...

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    2 i nstallation b lue h eat - j eep g rand c herokee 2-6 2.6 integration into fuel system important! Always cut fuel line with a sharp razor knife or razor. Do not cut with side cutters, scissors or similar tools as doing so will cause a restriction inside the fuel line. Important! Observe illustrat...

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    B lue h eat - j eep g rand c herokee 2 i nstallation 2-7 2-16: fuel standpipe installed in sender unit - top view 2-17: fuel standpipe with fuel line 2-15: fuel standpipe installed in sender unit – insert standpipe through hole in the sender unit and align outlet as shown in illustration 2-15. – ens...

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    2 i nstallation b lue h eat - j eep g rand c herokee 2-8 2-18: fuel pump installation site 2-19: fuel pump mounting position 2-20: fuel pump installed and connected – remove the screw at fuel filter. Screw will be used for mounting the fuel pump. Refer to illustration2-18. – fit p-clamp around fuel ...

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    B lue h eat - j eep g rand c herokee 2 i nstallation 2-9 2-21: fuel line routing along left frame rail 2-22: fuel line routing up to top left of bulkhead 2-23: fuel line routing along top of bulkhead to heater – route fuel line towards the front of vehicle along the left frame rail following the veh...

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    2 i nstallation b lue h eat - j eep g rand c herokee 2-10 2-24: heater installation site (shown with heater installed) 2-25: battery tray area - battery removed 2-26: engine mount bolts used for heater bracket 2.7 heater installation the webasto auxiliary coolant heater is to be installed on the rig...

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    B lue h eat - j eep g rand c herokee 2 i nstallation 2-11 note: the heater must be preassembled before installing. The next steps will detail the installation of the mounting bracket, fuel line connector, combustion air intake tube, exhaust tube and coolant lines. – attach the mounting bracket to th...

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    2 i nstallation b lue h eat - j eep g rand c herokee 2-12 note: two different styles of hose clamps are supplied in the installation kit. The wide band clamps are used on all coolant connections and the narrow band clamps will be used to attach the combustion air intake tube. Do not use the narrow b...

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    B lue h eat - j eep g rand c herokee 2 i nstallation 2-13 – place assembled heater into the installation location of the vehicle as shown in illustration 2-33. – slide bracket into place under receiver/dryer mount bolt and aligning heater bracket holes with upper engine mount bracket bolt holes. – r...

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    2 i nstallation b lue h eat - j eep g rand c herokee 2-14 2-38: fuel line to heater connection 2-37: air intake silencer - close-up 2-36: combustion air intake tube routing 2.9 combustion air intake tube – route combustion air intake tube from heater up and over the front of the heater and behind th...

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    B lue h eat - j eep g rand c herokee 2 i nstallation 2-15 2-41: coolant hose connections 2-40: coolant hose cutting 2-39: coolant hose preparation 2.11 integration into coolant system note: for a general understanding of the coolant circuit, turn to section 4 of this manual and observe 4.2, plumbing...

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    2 i nstallation b lue h eat - j eep g rand c herokee 2-16 2-43: main power connection to heater system 2-42: hoses connected and tied - view from front – tie hoses as shown in illustration 2-42 with nylon wire ties. Make sure to allow for engine movement. 2.12 power connection – install battery tray...

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    B lue h eat - j eep g rand c herokee 2 i nstallation 2-17 2.14 final inspection and initial start-up 2.14.1 final inspection inspect installation for: • loose fasteners. • exhaust system routing and clamp tightness. • combustion air intake tube routing and clamp tightness. • loose coolant line clamp...

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    2 i nstallation b lue h eat - j eep g rand c herokee 2-18 your notes and observations.

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    B lue h eat - j eep g rand c herokee 3 b asic t roubleshooting 3-1 3.1 general information this section describes troubleshooting procedures for the blueheat coolant heater within the scope of installation. Troubleshooting is normally limited to the isolation of defective components and provides inf...

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    3 b asic t roubleshooting b lue h eat - j eep g rand c herokee 3-2 caution diagnostics equipment is intended for use by webasto trained personnel at authorized webasto distributor, dealer and end user service facilities. A pc diagnostic interface kit for the blueheat is available that allows for mor...

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    B lue h eat - j eep g rand c herokee 4 s chematics 4-1 4. Schematics 4.1 wiring schematic.

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    4 s chematics b lue h eat - j eep g rand c herokee 4-2 4.2 plumbing schematic.

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    Webasto product n.A., inc. 3333 john conley drive lapeer, mi 48446 phone (810) 245-2400 toll-free (800) heater-1 fax (810) 664-7720 technical assistance hotline usa: (800) 555-4518 canada: (800) 667-8900 www.Webasto.Us org. 10/2002 rev. 01/2003 p/n 5000626a.