Webasto BlueHeat Installation Instructions Manual

Brand: Webasto

Model: BlueHeat

Type: Installation Instructions Manual

Jeep Grand Cherokee

2002-2003 4.0 Liter Gasoline

Installation Instructions

BlueHeat Coolant Heater

DOC. P/N 5000626A

KIT P/N 5000543A

TABLE OF CONTENTS BLUEHEAT - JEEP GRAND CHEROKEE

Table of Contents

1. Foreword

1.1 Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Meaning of Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 Additional Documentation to be Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.4 General Safety Regulations and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.4.1 General Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.5 Heater Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2. Installation

2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.3 Electrical Harness and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.4 Integrating Webasto Heater Blower Control with Vehicle Blower System . . . . . . . . . . . . . . 2-4

2.5 Timer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.6 Integration into Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.7 Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.8 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.9 Combustion Air Intake Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.10 Fuel Line Connection to Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.11 Integration into Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.12 Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.13 Concluding Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.14 Final Inspection and Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.14.1 Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.14.2 Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

3. Basic Troubleshooting

3.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Heater Lockout Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 General Malfunction Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.4 PC Diagnostics Interface Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

4. Schematics

4.1 Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Plumbing Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

BLUEHEAT - JEEP GRAND CHEROKEE 1FOREWORD

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 America, Inc. does not recommend

the installation and servicing of Webasto products by

untrained, unauthorized personnel or end-users.

Installations and servicing of Webasto products by

untrained, unauthorized personnel and end-users will

release Webasto Product North America, Inc. and Webasto

authorized distributors, dealers and their personnel from

responsibility for damage to Webasto product, any

resulting collateral property damage and personal injury.

Any use, operation, installation, modification or application

of the product not described in Webasto manuals, or

subjecting the product to extreme or unusual conditions

beyond the limits of specified performance characteristics is

misuse of the product.

Failure to comply with all installation instructions is a

misuse of Webasto product. The same applies for repairs

without using genuine Webasto service parts. This will

void the coolant heaters “Official Marks of Conformity.”

1.2 Meaning of Warning, Caution,

and Attention Headings

Warning, Caution and Attention headings in this manual

have the following meaning:

1.3 Installation Documentation

These non-binding installation instructions apply to the

Jeep Grand Cherokee 4.0 liter gasoline version model year

2002 - 2003 (without tow package), unless technical

modifications on the vehicle influence the installation,

excluding all liability claims. Depending on the version and

equipment in the vehicle, changes may be required to the

installation work set out in these installation instructions. In

any event, however, the directives in the “installation

manual” and “operating manual” Thermo Top Z/C/E must

be followed. Acknowledged engineering conventions must

be observed for the installation work.

Important! All relevant state and provincial

licensing regulations if any, governing the

installation and use of auxiliary heating devices

must be observed!

1.4 General Safety Regulations and

Information

The general safety regulations for the prevention of

accidents and relevant operating safety instructions must

be observed at all times.

The specific safety regulations applicable to this manual are

highlighted in the individual chapters by Warnings,

Cautions and Attention notations (see section 1.2).

1.4.1 General Safety Notes

The heater must not be installed in the passenger

compartments of the vehicle. Should the heater be

installed in such a compartment, the installation box must

be sealed tight against the vehicle interior. There must be

sufficient ventilation of the installation box from the

exterior in order not to exceed a maximum temperature of

60 °C (140 °F) in the installation box. Excessive

temperatures may cause malfunctions.

ATTENTION!

This heading is used to highlight and draw specific

attention to information.

CAUTION

This heading is used to highlight that

non-compliance with instructions or procedures may cause

damage to equipment.

WARNING

This heading is used to highlight that

non-compliance with instructions or procedures may cause

injuries or lethal accidents to personnel.

WARNING

Due to the danger of poisoning and suffocation, the

heater must not be operated in enclosed areas, such as

garages or workshops, without an exhaust venting system,

not even if the start-up is activated by the timer or remote

start device.

At filling stations and fuel depots the heater must be

switched off as there is a potential danger of explosions.

Where flammable fumes or dust may build up (e.g. in the

vicinity of fuel, coal, wood, cereal grain deposits or similar

situations) the heater must be switched off to prevent

explosions.

1FOREWORD BLUEHEAT - JEEP GRAND CHEROKEE

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 the coolant level, proceed in accordance

with the vehicle manufacturer’s instructions.

The coolant in the heating circuit of the heater must

contain a minimum of 10% of a quality brand glycol based

anti-freeze.

Extracting combustion air from the vehicle interior is not

permissible under any circumstance.

The exhaust pipe outlet is to be positioned below the

vehicle floor, to the nearest possible location of the

vehicle’s left or right side.

Exhaust pipes must be routed so that exhaust fumes will

not penetrate into the vehicle’s interior. Condensation

accumulation in the exhaust pipe must be directly drained.

A condensation drain hole may be provided as required.

Do not route exhaust pipes and components within

100mm (4 inches) of flammable materials such as

polyurethane or similar foam insulation, styrene sheet

insulation, fuel tanks and containers, glycol reservoirs,

coolant lines, wood and paper products, carpet, tires,

electrical wiring, brake and air lines or any materials

deemed to be flammable or heat sensitive.

Do not terminate exhaust above flammable materials such

as polyurethane or similar foam, insulation, styrene sheet

insulation, fuel tanks and containers, glycol reservoirs,

coolant lines, wood and paper products, carpet, tires,

electrical wiring, brake and air lines or any materials

deemed to be flammable or heat sensitive.

Electrical lines, switch gear, and control gear of the heater

must be located in the vehicle so that their proper function

cannot be impaired under normal operating conditions.

The function of any parts vital for vehicle operation must

not be impaired.

The operational state of the heater, i.e. an indication

“on” or “off”, must be clearly visible to the operator.

The coolant heater may only be operated within the

specified operating voltage range designated by type.

The coolant heater may only be operated with the specified

fuel as recommended by the vehicle manufacturer.

For the routing of fuel lines, the following important

regulations must be adhered to:

• Fuel lines are to be installed in such a way that they

remain unaffected by torsional stresses created by

vehicle and engine movement. They must be

protected against mechanical damage. Fuel lines

must be securely fastened to the vehicle every 12

inches (30 cm.) or less along the total length from

heater to fuel tank. Fuel-carrying parts are to be

protected against excessive heat and are to be

installed so that any dripping or evaporating fuel can

neither accumulate nor be ignited by hot components

or electrical equipment.

• In buses, fuel lines are not to be located in the

passenger area or in the driver’s compartment.

Fuel supply must not be by means of gravity or

pressurization of the fuel tank.

• The fuel tank must either be equipped with a vent

cap or be ventilated in another way (ventilation line).

• The operational state of the heater, i.e. an indication

“on” or “off”, must be clearly visible to the operator.

BLUEHEAT - JEEP GRAND CHEROKEE 1FOREWORD

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 illustration 1.

5 1 2 3 6

Legend for Illustration 1

1 Webasto Heater

2 Fuse Holder and Blower Relay

3 Digital Timer

4 Exhaust Tube

5 Combustion Air Intake Tube

6 Fuel Metering Pump

Illustration 1

Illustration 2

1FOREWORD BLUEHEAT - JEEP GRAND CHEROKEE

1-4

BLUEHEAT - JEEP GRAND CHEROKEE 2INSTALLATION

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 present. If fuel quantity is greater than ¼ of capacity, make

provisions to reduce quantity of fuel

2. Disconnect negative terminal of vehicle battery(s).

3. Remove lower instrument panel fascia (above steering column) to gain access to timer and blower motor harness.

Refer to vehicle manufacturer’s instructions for removal.

4. Remove the ash tray and center console fascia. Refer to vehicle manufacturers instructions for removal.

5. Protect vehicle fenders with fender covers and protect seating surfaces against soiling.

CAUTION

Do not deviate from the installation instructions provided in this manual. Location of heater, installation of coolant lines,

fuel system and components, wiring and control devices are important for proper operation. Failure to comply with the

installation instructions provided may result in poor operation or damage to heater and vehicle components.

2. Installation

2.1 General Information

The installation instructions provided will take you step by step through the installation process. Follow all directions

carefully and read all Warnings, Cautions and Notations as you work through these instructions and the installation of the

BlueHeat coolant heater.

2.1.1 Tools Required

1/4” Drive Ratchet

1/4” Drive 4 inch extension

10 mm six point socket, 1/4” drive

10 mm six point deep well socket, 1/4” drive

3/8” Drive Ratchet

3/8” Drive 12 inch extension

13 mm socket, 3/8” drive

15 mm socket, 3/8” drive

17 mm socket, 3/8” drive

10 mm combination wrench

8 mm nut driver

Phillips #2 screwdriver

Combination side-cut/crimping pliers

Hose clamping pliers

Hose cutting pliers

Drill

2.5 mm (3/32 in.) drill bit

8 mm (5/16 in.) drill bit

10 mm (25/64 in.) drill bit

Hacksaw

Utility Knife

Mechanic’s wire - 2 feet

Hoisting equipment and safety stands

Vehicle manufacturer’s service reference manual

2INSTALLATION BLUEHEAT - JEEP GRAND CHEROKEE

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 the

hood at the passenger side of the bulkhead. Use a

serrated washer between the bulkhead and the ground

plate to ensure a good ground. Refer to illustration 2-2.

– Mount fuse block/relay bracket on the stud located just

left of the ground stud used in step 2. Refer to

illustration 2-3.

– Attach fuse block mounting plate to fuse block

mounting bracket using supplied screw and lock-nut.

Refer to illustration 2-3.

– Snap fuse block onto fuse block mounting plate. Refer

to illustration 2-3.

– Attach relay to mounting bracket using supplied

self-tapping screw as shown in illustration 2-3.

2-1: Harness Configuration

2-2: Harness Ground

2-3: Fuse Block/Relay Mount Location

Fuse Block

(under hood

location)

To Heater

To Power

Source

To Timer &

Optional

Remote

2 - Diagnostic Connecter (Unused)

1 - Supplemental Heat

Connection (Option)

Blower

Activation To Fuel

Pump

Fuse Block

Relay

Fuse Mounting Plate

Mounting Bracket

Mounting Stud

Ground Plate Ground Stud

BLUEHEAT - JEEP GRAND CHEROKEE 2INSTALLATION

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.

– Loosely tie harnesses to existing vehicle lines etc.

with nylon wire ties as shown in illustration 2-4.

NOTE: Do not fully tighten nylon wire ties until

the fuel line is routed later in the installation of

the fuel system.

– Cut a ½ inch hole in the bulkhead grommet. Route the

timer harness and blower control harness through the

hole into the drivers foot-well area. Refer to illustration

2-5.

– Route the fuel pump harness down the left side of the

bulkhead allowing it to hang down. The fuel pump

harness will be routed to a point near the vehicle fuel

filter later during the fuel system installation. Do not

secure harness with nylon ties at this time.

– Remove the left instrument panel lower fascia (above

steering column) if you have not done so already during

vehicle preparations step 3. Refer to vehicle

manufacturers instructions for removal.

– Remove the ash tray and center console fascia if you

have not done so already during vehicle preparations

step 4. Refer to vehicle manufacturers instructions for

removal.

– Locate timer and blower control harnesses from inside

drivers foot well area and pull harnesses through main

grommet. Refer to illustration 2-6.

2-4: Timer and Blower Control Harness Routing

2-5: Main Bulkhead Grommet Access for Harnesses

2-6: Main Bulkhead Grommet Access - Inside View

Timer/Blower Harnesses

Grommet

Timer/Blower

Harnesses

Fuse Block Timer/Blower Harnesses

Brake Booster

2INSTALLATION BLUEHEAT - JEEP GRAND CHEROKEE

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 tray opening.

2.4 Integrating Webasto Heater Blower

Control with Vehicle Blower System

– Locate vehicle blower control harness as shown in

illustration 2-8.

– Carefully cut open the vehicle blower control switch

harness loom and locate the white/pink wire from the

loom as shown in illustration 2-9.

– Cut the white/pink wire in the blower control harness as

shown in illustration 2-9.

– Connect the black wire from the Webasto blower

control harness to the control (switch) side of the

white/pink wire of the vehicle blower control harness

using the spade connectors supplied.

NOTE: Alternate spade connections i.e. Male to

female on one wire and female to male on the

other. This will allow easy re-connection of OEM

system in the event the heater system is removed

in the future.

– Connect the red wire from the Webasto blower control

harness to the blower (motor) side of the white/pink

wire of the vehicle blower control harness using the

spade connectors supplied.

IMPORTANT! Ensure that connections are done

correctly. Wiring connections must be properly

oriented.

2-7: Timer Harness & Blower Control Harness Routing

2-8: Vehicle Blower Control Harness (Center Console)

2-9: Blower Control Integration - Wire Splicing

Cut

Timer Harness

Blower Harness

White/Pink

Wire

BLUEHEAT - JEEP GRAND CHEROKEE 2INSTALLATION

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 hidden components behind the

panel that may be damaged or interfere with the

timer installation!

– After selecting a site for the timer, temporarily apply the

timer mounting template. Refer to illustration 2-10 for

a translated sample of the template.

– As specified on template, drill the 10 mm (25/64in.) and

the 2.5 mm (3/32 in.) holes.

– Remove drilling template.

– Route the timer harness through the 10 mm (25/64 in.)

hole.

– Apply foam cushion to back of timer.

– Carefully align timer harness plug with socket on rear of

timer and push into socket until seated.

– Place the timer into position and secure with screw

provided until the timer with foam cushion is firmly

seated against panel. Tighten screw no more than

0.8 Nm (7.0 lb-in.). DO NOT OVER TIGHTEN!

– Refer to illustration 2-11 for a completed timer

installation example.

Timer

2-10: Timer Installation Template (NOT TO SCALE!)

2INSTALLATION BLUEHEAT - JEEP GRAND CHEROKEE

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 illustration 2-12 for correct

fuel line connecting.

– Lower the fuel tank enough to gain access to sender

unit area according to the vehicle manufacturers service

procedures and support tank on jack stands.

– Remove fuel sender unit according to the vehicle

manufacturers service procedures.

– Using a 8 mm (5/16 in.) washer, mark the location for

the fuel standpipe as shown in illustration 2-13.

– Drill a 8 mm (5/16 in.) hole through the sender unit at

the location marked in illustration 2-13. Check for

obstructions before drilling.

– Locate the standpipe assembly provided in the

installation kit. Refer to illustration 2-14.

2-13: Fuel Standpipe Location

2-14: Fuel Standpipe Assembly

2-12: Correct Vs. Incorrect Fuel Line Connections

CAUTION

Full to partially filled fuel tanks are heavy and awkward to

handle. In the event the fuel tank must be removed to

gain access to the sender unit, ensure tank is near empty.

To prevent accidents and potential injury to personnel,

make sure tank is well supported prior to removing

mounting hardware.

Standpipe

Location

Banjo Bolt

Banjo Fitting

Standpipe

Sealing Washer (Black)

Sealing Washer (Brass)

Fuel Tank/Sender Unit

Lock Nut

BLUEHEAT - JEEP GRAND CHEROKEE 2INSTALLATION

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.

– Ensure standpipe does not interfere with fuel sender

float assembly. Bend standpipe to clear if necessary.

– Mark standpipe length to approximately 25 mm (1 in.)

from tank bottom and cut off excess at a 45° angle.

IMPORTANT! Keep the bottom of the standpipe

above the vehicles pickup tube.

– Secure in place with lock nut. Tighten nut to 9.0 Nm.

– The banjo outlet fitting should be aligned as shown in

illustration 2-16. If outlet is not aligned as shown,

loosen banjo nut and realign. Tighten the banjo nut to

9.0 Nm.

– Install fuel sender unit according to the vehicle

manufacturers service procedures.

– Assemble one rubber fuel line connector with two hose

clamps and push onto banjo fitting outlet. Tighten

inboard clamp. Refer to illustration 2-17.

– Fully insert supplied Mecanyl fuel line into connector

and tighten outboard clamp.

– Connect vehicle fuel lines and electrical connections on

fuel sender.

– Loop webasto fuel line in the same manner as the

vehicle fuel lines are at the sender unit to allow slack for

servicing. Continue routing fuel line to vehicle fuel filter

area. Secure heater fuel line to vehicle fuel lines with

nylon ties. Refer to illustration 2-17.

– Install the fuel tank according to the vehicle

manufacturers service procedures.

Standpipe

2INSTALLATION BLUEHEAT - JEEP GRAND CHEROKEE

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 pump. Secure to vehicle using

screw removed in previous step. Position as shown in

illustration 2-19 with connector socket pointed towards

front of vehicle.

ATTENTION! Fuel pump must be mounted

horizontally in order to operate properly and

ensure correct fuel metering to the heater.

– Pre-assemble two rubber fuel line connectors with two

hose clamps each. Push rubber fuel line connectors

onto pump inlet and outlet and tighten inboard hose

clamps on both connectors leaving outboard clamps

loose.

– Insert fuel line from fuel tank into fuel pump inlet

connector fully. Tighten outboard hose clamp. Refer to

illustration 2-20.

– Insert fuel line that will connect to heater into fuel

pump outlet connector fully. Tighten outboard hose

clamp. Refer to illustration 2-20.

– Route fuel pump harness from front of vehicle along

inside left frame rail and connect to fuel pump electrical

receptacle.

Vehicle Fuel Filter

Screw for Fuel

Pump

Front

Screw

Webasto Fuel Pump

Fuel Pump Harness

Fuel Line from Tank

Fuel Line to Heater

BLUEHEAT - JEEP GRAND CHEROKEE 2INSTALLATION

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 vehicle fuel lines and fuel

pump harness. Refer to illustration 2-21.

– Secure fuel line and fuel pump harness to vehicle fuel

lines, etc. with nylon wire ties. Refer to illustration 2-21.

– Continue routing fuel line by following the fuel pump

harness up and to the top of the bulkhead as shown in

illustration 2-22.

– With the vehicle lowered, pass the fuel line through the

nylon wire ties used to loosely secure timer/blower and

fuel pump harness as shown in illustration 2-23.

– Continue along to the webasto fuse block and then

down to the heater installation site. Refer to

illustration 2-23.

– Pull nylon wire ties along bulkhead tight securing

timer/blower harnesses, fuel pump harness and fuel

line. Refer to illustration 2-23.

Front

Fuel Line

Left Frame Rail

Front

Route Fuel Line up

to Top Left Side of

Bulkhead

Fuse Block Fuel Line

Wire Ties

2INSTALLATION BLUEHEAT - JEEP GRAND CHEROKEE

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 right hand side of the engine compartment next to

the engine as shown in illustration 2-24.

– Unfasten vehicle fuse box to allow removal of battery

tray.

– Remove battery temperature sensor and nylon ties.

– Remove vehicle battery and battery tray.

NOTE: You may wish to disconnect the positive

connection at the alternator to gain working room

for installation of the heater and bracket.

– Loosen the bolt that secures the A/C receiver/dryer.

Refer to illustration 2-25.

– Remove the two upper right engine mount bracket

bolts that will be used to secure the heater bracket.

Refer to illustration 2-26.

Upper Mount Bolts (Remove)

Front

Receiver/Dryer

Receiver/Dryer Bolt (Loosen)

BLUEHEAT - JEEP GRAND CHEROKEE 2INSTALLATION

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 the heater. Place two

spacer washers (supplied) between heater and

mounting bracket as indicated in illustration 2-27.

(In later kits, the mounting bracket may already be

attached by Webasto).

– Take a 90° fuel line connector from the kit. Place one

fuel line clamp on one end and push connector onto

fuel inlet nipple. Position elbow straight up and tighten

clamp. Refer to illustration 2-28.

– Take the formed coolant hose supplied in the kit and cut

hose according to cutting diagram. Refer to illustration

2-29.

2-27: Heater Assembly - Mounting Bracket Installed

2-29: Coolant Hose Cutting Diagram

2-28: Heater Assembly - 90° Fuel Line Connector

394 mm (15 1/2 in.) 350 mm (13 3/4 in.)

Place 2 Spacer

Washers Between

Heater and Bracket

Fuel Line Clamp

90° Fuel Line Connector

2INSTALLATION BLUEHEAT - JEEP GRAND CHEROKEE

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 band clamps to connect the coolant lines!

– Install 180° curved coolant hose onto heater coolant

pump inlet. Secure with a wide band hose clamp.

Tighten clamp to a torque of 15 lb-in. Refer to

illustration 2-30.

– Install straight coolant onto heater coolant outlet port.

Secure with a wide band hose clamp. Tighten clamp to

a torque of 15 lb-in. Refer to illustration 2-30.

IMPORTANT! The coolant outlet port and the

combustion air inlet port look similar to one

another. To tell them apart, the coolant outlet has

a hose barb on the end while the combustion air

inlet port is smooth with no barb. Reference

illustrations 2-31 and 2-32.

– Attach 90° exhaust elbow to heater exhaust outlet

(exhaust tube will be installed later).

Direct elbow towards the back of the heater (opposite

direction of coolant outlet). Secure with supplied

exhaust clamp as shown in illustration 2-31.

– Connect split end of combustion air intake tube to the

heater combustion air intake port. Secure with a

narrow band clamp provided. Refer to illustration 2-32.

IMPORTANT! The combustion air inlet port and

coolant outlet port look similar to one another.

To tell them apart, the coolant outlet has a hose

barb on the end while the combustion air inlet

port is smooth with no barb. Reference

illustrations 2-31 and 2-32.

2-30: Heater Assembly - Inlet Hose

2-32: Heater Assembly - Combustion Air Intake Tube

2-31: Heater Assembly - Exhaust Elbow

Coolant Inlet Hose

Coolant Outlet

(with hose barb)

Exhaust Elbow

Air Inlet Port

Exhaust Clamp

Coolant Pump

Coolant Outlet Hose

Combustion Air

Intake Tube

BLUEHEAT - JEEP GRAND CHEROKEE 2INSTALLATION

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.

– Reinstall upper engine mount bracket bolts and tighten.

Tighten receiver/dryer bolt.

2.8 Exhaust System

– Raise vehicle to access underside of vehicle and bottom

of heater.

– Using the full length of exhaust tube and heat insulating

sleeve supplied in the kit, slide exhaust tube through the

heat insulating sleeve.

– Route exhaust tube down and under the heater, overtop

of the right engine mount inside of the frame rail. Refer

to illustration 2-34.

NOTE: Once routed, the exhaust tube should be

between the heater bottom and the top of the right

engine mount.

ATTENTION! DO NOT route exhaust tube under

the right engine mount or cross-member.

Interference with the suspension will result in

damage to the exhaust tube.

– Attach exhaust tube to the heater outlet elbow.

Secure with an exhaust clamp.

– Continue routing the exhaust tube towards the front of

the vehicle.

– With a pipe clip, attach the exhaust to the frame at a

point immediately behind the right vehicle stabilizer bar

using an existing frame screw. The pipe clip hole will

have to be enlarged to accommodate the frame screw.

Refer to illustration 2-35.

– Bend and shape the exhaust tube downward to a point

slightly below the bottom of the bumper under-ride

shield.

Note: If “Goosenecks” cannot be avoided in the

exhaust tube, drill a 5 mm (3/16 in.) hole at the

lowest point of each gooseneck to allow drainage

of trapped condensation. 2-35: Exhaust Tube - View from Inside of Frame Rail

2-34: Exhaust Tube Routing - from Heater

2-33: Heater in Installation Location

Heater

Coolant Pump

Front

Exhaust Tube

Pipe Clip

Front

Exhaust Tube

with Insulating

Sleeve

Heater

Front

Stabilizer

Bar Bracket

2INSTALLATION BLUEHEAT - JEEP GRAND CHEROKEE

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 the mounting

bracket as shown in illustration 2-36.

– Trim combustion air intake tube to length and attach air

intake silencer. Refer to illustration 2-36 and 2-37.

– Drill a 6 mm (1/4 in.) hole through the bracket at the

point indicated in illustration 2-37.

NOTE: This step may not be required on later kits.

Arrangements with the manufacturer of the

mounting bracket has been made to have this hole

predrilled.

– Place the air silencer holding strap around the silencer

and push the pin through the 6 mm (1/4 in.) hole.

Refer to illustration 2-37.

2.10 Fuel Line Connection to Heater

– Place a fuel clamp on the 90° rubber fuel line connector.

– Using a razor knife, cut the white fuel line to length and

insert into the rubber fuel line connector. Refer to

illustration 2-38.

– Tighten fuel line clamp.

Holding Strap Pin

Silencer

Front

Heater

Combustion Air Tube

Silencer

6 mm (14 in.)

Hole

Front

Combustion Air Tube

Fuel Line Connector

Fuel Line Clamp

Fuel Line

Page is loading ...

Webasto BlueHeat Installation Instructions Manual

Webasto BlueHeat Installation Instructions Manual

Webasto BlueHeat Installation Instructions Manual

Related papers

Other documents