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 equ...
Dodge caliber 1311556a 2 table of contents validity vehicle and engine types, equipment variants as well as 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...
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 exclu...
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. Specif...
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 fro...
Dodge caliber 1311556a 6 electrical connections connecting the ground wire 1 chassis ground point 2 ground wire installing the heater unit cable harness 1 heater unit cable harness to original vehicle lines cable harness installation diagram fuse holder, k3 relay 1 fuse holder retaining plate, bore ...
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 g...
Dodge caliber 1311556a 8 time switch 1 time switch assem- bling the time switch summer / winter switch option 1 bore hole Ø 12 mm, summer / winter switch assem- bling the summer / winter switch remote start option position the bracket 3 according to the illustration. 1 bolt m5x16, m5 flanged nut in ...
Dodge caliber 1311556a 9 temperature sensor for htm100 only 1 temperature sensor, fasten as appropriate assem- bling the temperature sensor thermo call option 1 Ø 4mm bore hole, 5.5x13 self-tapping screws [4x each] 2 receiver (to the left next to the steering column) assem- bling the receiver 1 ante...
1311556a 10 dodge caliber preparing the installation location 1 rivet nut m8 in available bore hole inserting rivet nuts loosely pre-assemble the bracket 1 and with bolt m8x30 2 on the rivet nut. 3 copy the hole image copy the hole image remove the bracket 1 Ø 12.5mm bore hole, tighten m8 rivet nut ...
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 1 extension for the circulation pump cable harness slide on cable harness a = 350mm b = 350mm c = 90mm d = 80mm e = 620mm dispo...
1311556a 12 dodge caliber 1 strut 2 loosely pre-fit ejot screw bolt loosely preassem- ble the strut on the heater unit connect the circulation pump cable harness and the extension with the butt connectors 4 of the same color. 1 rubberized tube clamp Ø 48mm 2 circulation pump 3 m6x20 bolt, flanged nu...
1311556a 13 dodge caliber ejot screw bolt tightening torque 10 nm! Insert two washers between the heater unit and the bracket in position 2. 1 ejot screw bolt [2x] 2 ejot screw bolt, washer [2x] pre- assem- bling the bracket on the heater unit 1 Ø 27mm hose clamps [2x] 2 connecting pipe 20x20 [2x], ...
1311556a 14 dodge caliber installing the heater unit prior to assembly, put on the heater unit cable harness 1 m8x30 bolt, spring washer, washer [2x each] on prepared rivet nuts assem- bling the heater unit 1 m6 flanged nut to original vehicle stay bolts 2 strut assem- bling the heater unit 30 1 1 3...
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...
Dodge caliber 1311556a 16 fuel line from the heater unit 1 on the pressure side of the metering pump [side with connector]. 2 hose section, Ø 10 mm hose clamps [2x]. 3 metering pump cable harness, single wire seals [2x], flat connector [2x], connector housing connec- ting to metering pump remove tan...
Dodge caliber 1311556a 17 fuel line from the tank extracting device 3 on 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. 2 hose section, Ø 10 mm hose clamps [2x]. Connec- tion to metering...
Dodge caliber 1311556a 18 exhaust system 1 exhaust pipe a = 820mm 2 exhaust end section b = 180mm preparing the exhaust pipe 1 angle bracket 2 m6x20 bolt, m6 flanged nut on existing hole assem- bling the angle bracket 1 exhaust silencer 2 m6x20 bolt, m6 flanged nut on bracket assem- bling the spacer...
Dodge caliber 1311556a 19 1 exhaust pipe 2 tube clamp, m6x20 bolt, flanged nut m6 on fastening strap 3 slide the rubber profile onto the exhaust line. 4 fastening strap with holes 5 m6x25 bolt, flanged nut on existing hole assem- bling the exhaust pipe 1 align rubber profile according to the illustr...
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...
Dodge caliber 1311556a 21 disconnect engine outlet hose 2 from heat exchanger inlet supports. Dispose of spring band clamp 1. Splitting point 1 connect engine outlet hose section with hose a connec- ting engine outlet connect hose f (enclosed 180° bend) with hose e and connect to the heat exchanger ...
Dodge caliber feel the drive webasto ag po box 80 - 82132 stockdorf hotline 01805 / 932278 - hotfax 0395 / 5592-353 http://www.Webasto.De printed in germany 02/2007 printed by: steffen 1311556a final work warning! Reassemble disassembled components in reverse order. Check that all hose lines, clips,...
Dodge caliber 1311556a 23 operating instructions for the end customer please remove page and add to the vehicle operating instructions. Note: we recommend adjusting the heating time to the driving time heating time = driving time example: for a driving time of 20 minutes (one way) we recommend not e...
Dodge caliber 1311556a 24 0 100mm 100mm 75 90° scale 1:1 compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimize margins” and 100% of the normal size. Torsion line Ø 10.5mm fastening strap template for th...
Dodge caliber 1311556a 25 tank extracting device template 0 100mm 100mm scale 1:1 compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimize margins” and 100% of the normal size..
