Water Heater

Water Heater

Water Heater

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.: 1316728A_EN Fee Euro 10.00 © Webasto AG Suzuki Swift 1.2 Petrol from Model Year 2011 Left-hand drive vehicle Gear box Feel the drive Thermo Top Evo Parking Heater e1 00 0258

Water Heater

Suzuki Swift 1316728A_EN 2 Table of Contents Validity Vehicle and engine types, equipment variants and national specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation 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 Swift NZ e4 * 2007 / 46 * 0155 . . Engine type Engine model Output in kW Displacement in cm³ K12B Petrol 69 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 Preparing electrical system 6 Electrical system 8 Fan control for manual air conditioning 10 Automatic air-conditioning fan control 11 Digital timer 13 Remote option (Telestart) 13 Preparing installation location 14 Preparing heater 15 Installing heater 16 Fuel 17 Coolant circuit 20 Combustion air 23 Exhaust gas 24 Final Work 27 Template for Fuel Standpipe 28 Operating Instructions for End Customer 29

Water Heater

Suzuki Swift 1316728A_EN 3 Heater / Installation Kit Foreword This installation documentation applies to Suzuki Swift 1.2 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 Instal- lation 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. 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).

When installing an IPCU, the corresponding settings must be checked or adjusted 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 Swift 2011 1.2 Petrol 1316727A 1 Heater control see price list

Water Heater

Suzuki Swift 1316728A_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. Reference to general installation instructions of Webas- to components or to the manufacturer's vehicle-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 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.

Water Heater

Suzuki Swift 1316728A_EN 5 Preliminary Work WARNING! - Open fuel tank cap, ventilate tank. - Close the fuel tank cap again. - 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. - Disconnect and remove battery. - Remove air filter fully with intake hose - Detach the wheel well trim on the right and left. - Remove the bumper.

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

- Remove the lower instrument panel trim on the front passenger side - Removing instrument panel trim on driver's side Remove page 29 "Operating Instructions for End Customer" and add to the vehicle operating instruc- tions. Heater installation location 1 Heater Installa- tion loca- tion 1 1

Water Heater

Suzuki Swift 1316728A_EN 6 Preparing electrical system Manual air conditioning Wire sections retain their numbering in the whole document. Produce connections as shown in wiring dia- gram. Inserting fuse F4, preparing K1 relay Insert fuse F4 25A 3. Insert red (rt) wire1 in socket K1/87a a black (sw) wire 2 in socket K1/30. K1 relay will be inserted later after the installation. 4 Fuse holder of passenger compartment Preparing fuseholder of passen- ger com- partment Automatic air-conditioning Wire sections retain their numbering in the whole document.

Cutting wires to length Produce connections as shown in wiring dia- gram.

Inserting fuses F4 and F5, preparing K1 relay 86 85 30 87a 87 K1 gn/ws 0,75² F4 br 0,5² rt 4² rt/sw 0,5² F3 1 2 sw 4² rt 4² 2 3 4 2 1 1 100 5 sw 0,5² 200 2 400 6 86 85 30 87a 87 K1 gn/ws 0,75² F4 br 0,5² rt 4² rt/sw 0,5² F3 3 4 sw 4² rt 4² 1 2 F5

Water Heater

Suzuki Swift 1316728A_EN 7 Insert black (sw) wire 1 along with black (sw) wire 4 in socket K1/30. Insert black (sw) wires 1 and 2 in fuse holder F5. Insert red (rt) wire 3 in socket K1/87a. Install wire sec- tion 2 in protective sleeving provided. Insert fuses F4 25A 5 and F5 10A 7. K1 relay will be inserted later after the installation. 6 Fuse holder of passenger compartment Preparing fuseholder of passen- ger com- partment 3 5 6 7 1 4 2 3

Water Heater

Suzuki Swift 1316728A_EN 8 Electrical system Fuse holder of engine compartment 1 Angle bracket 2 M6x20 bolt, flanged nut, existing hole 3 M5x16 bolt, large diameter washer [2x], re- taining plate of fuse holder, nut 4 Fuses F1-2 mounted Positive wire 1 Positive wire on positive distributor of battery Wiring har- ness rout- ing diagram Earth wire 1 Earth wire to original vehicle earth point Wiring harness pass through 1 Protective rubber plug 4 4 3 1 2 5 1 Do not install the metering pump wiring harness until later togeth- er with fuel line along the original vehicle fuel lines on the under- body 6 1 7 1

Water Heater

Suzuki Swift 1316728A_EN 9 Connect same colour wires of wiring harness of passenger compartment fuse holder 1 to wiring harness of heater 2 according to wiring diagram. Connect- ing wiring harnesses Insert 10 mm shim between fuse holder of passenger compartment 1 and cross mem- ber. After installation, mount the K1 relay 2. 1 Fuse holder of passenger compartment 3 M5x20 bolt, large diameter washer, 10 mm shim, flanged nut, existing hole Installing fuseholder of passen- ger com- partment 8 1 2 9 1 2 3

Water Heater

Suzuki Swift 1316728A_EN 10 Fan control for manual air conditioning Wiring dia- gram Webasto components Vehicle components Colours and symbols Legend HG Heater TT Evo GR Fan relay rt red X1 6-pin heater connector GM Fan motor sw black X2 2-pin heater connector WG Resistor group ge yellow X10 4-pin connector Heater control F4 30A fuse gn green br brown K1 Fan relay ws white F1 20A fuse F2 30A fuse X Cutting point F3 1A fuse Wiring colours may vary.

F4 25 A fuse Connection to 2-pin connector 3 from the fan motor. Produce connections as shown in wiring dia- gram.

1Red (rt) wire from K1/87a 2Black (sw) wire from K1/30 4 Black/yellow (sw/ge) connector of fan mo- tor 5 Black/yellow (sw/ge) wire of fan relay Connect- ing fan mo- tor Webasto 31 30 15 Suzuki HG X2 1 2 X1 5 2 F2 F1 br 0,5² gn/ws 0,75² ge 0,5² rt/sw 0,5² rt 4² br 0,5² X10 86 85 30 87a 87 K1 gn/ws 0,75² F4 br 0,5² rt 4² rt/sw 0,5² F3 GR + - GM M WG 2 1 4² sw rt 4² sw/ ge sw/ ge F4 10 3 5 2 1 4

Suzuki Swift 1316728A_EN 11 Automatic air-conditioning fan control Wiring dia- gram Webasto components Vehicle components Colours and symbols Legend HG Heater TT Evo GM Fan motor rt red X1 6-pin heater connector GR Fan relay ws white X2 2-pin heater connector GRr Fan controller sw black X10 2-pin connector Heater control F Fuses of vehicle br brown A/C V A/C booster gn green K1 Fan relay G20 40-pin connector A/C V ge yellow F1 20A fuse KB Air-conditioning control panel F2 30A fuse G227 Connector KB Insulate wire ends and tie back F3 1A fuse UK Fresh / recirculating air flap F4 25 A fuse A 7-pin connector UK X Cutting point F5 10A fuse Wiring colours may vary.

HG X2 1 2 X1 5 2 F2 F1 gn/ws 0,75² ge 0,5² rt/sw 0,5² rt 4² X10 br 0,5² br 0,5² 86 85 30 87a 87 K1 gn/ws 0,75² F4 br 0,5² rt 4² rt/sw 0,5² F3 3 4 sw 4² rt 4² 1 2 F5 GR + - GM M sw/ge sw/ ge F Webasto 31 30 15 Suzuki F ! rt/ws rt/ws sw 0,5² sw 0,5² GRr UK M 7 A/C V G20 36 37 38 KB G227 4 rt/ ws G20 15 14 13 !

5 sw 0,5² 6 rt/ws rt/ws rt/ws rt/ws sw 0,5² ! A

Suzuki Swift 1316728A_EN 12 Connection to 2-pin connector 1 from the fan motor. Produce connections as shown in wiring dia- gram. 2 Black/yellow (sw/ge) connector of fan mo- tor 3Red (rt) wire from K1/87a 4Black (sw) wire from K1/30 5 Black/yellow (sw/ge) wire of fan relay Connect- ing fan mo- tor Connection on 40-pin connector G20 8 of A/C booster and on connector G227 4 of A/C heater control panel. Produce connections as shown in wiring diagram. 1 Insulate red/white (rt/ws) wire of terminal 15 and tie back 2Black (sw) wire of fuse F5 10A 3 Red/white (rt/ws) wire from connector of G227 Pin 4 5Additional black (sw) wire 6Additional black (sw) wire 7 Insulate red/white (rt/ws) wire of original vehicle fuse and tie back 9 Red/white (rt/ws) wire from connector of G20 Pin 38 Connect- ing A/C booster and A/C control panel Connect to 7-pin connector 3 of the fresh and recirculating air flap.

Produce connections as shown in wiring dia- gram. 1 Insulate red/white (rt/ws) wire of terminal 15 and tie back 2 Red/white (rt/ws) wire from connector of fresh and recirculating air flap Pin 7 6Additional black (sw) wire Connect- ing fresh / recirculat- ing air flap 11 1 5 4 3 2 12 7 9 3 1 2 6 5 4 8 13 3 2 1 6

Suzuki Swift 1316728A_EN 13 Digital timer 1 Digital timer Installing digital tim- er Remote option (Telestart) 1 Original vehicle bolt 2 Bracket 3 Receiver Installing receiver 1 Antenna Installing antenna Temperature sensor T100 HTM Fasten temperature sensor 1 with adhesive tape.

Installing tempera- ture sensor 1 14 3 15 1 2 3 1 16 1 17

1316728A_EN 14 Suzuki Swift Preparing installation location Drill existing hole to 9.1 mm dia. and install rivet nut1 Installing rivet nut Install bracket 2 loosely, align vertically 1 Copy hole pattern [3x] 3 M6x20 bolt Copying hole pat- tern Removing bracket 1 9.1 mm dia. hole, rivet nut [3x each] Installing rivet nut Insert shims between bracket 2 and frame side member! 1 M6x30 bolt, spring lockwasher, 10mm shim [2x each] 3 M6x40 bolt, spring lockwasher, 10 mm shim, 5 mm ship [2x each] Installing bracket 18 1 19 1 3 1 1 2 20 1 1 1 21 1 2 3 1 3

1316728A_EN 15 Suzuki Swift Preparing heater 1 Coolant connecting piece, sealing ring [2x each] 2 5x15 self-tapping bolt, retaining plate of coolant connection pieces Installing coolant connec- tion pieces Tap thread with 5x13 self-tapping screw 1 [4x] and install loosely (turn max.

3 threads) Premount- ing bolts loosely Discard section X Hose A = 180°, 20 mm dia. moulded hose B = 240 C = 60 D = 150 E = 160 F = 100 G = 620 Cutting hoses to length All spring clips = 25 mm dia. 1 90°, 18x18 mm connecting pipe [3x] Premount- ing hoses 22 1 1 2 23a 1 1 1 1 23b B X C D E F G A C 24 1 F E D 1 1 G

1316728A_EN 16 Suzuki Swift Installing heater Route premounted hoses to the engine com- partment. 1 5x13 self-tapping bolt [2x] Installing heater 1 5x13 self-tapping bolt [2x] Installing heater 1 Metering pump wiring harness 2 Wiring harness of heater [2x] Mounting wiring har- nesses 25 1 1 26 1 1 27 1 2 2

Suzuki Swift 1316728A_EN 17 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.

Complete connector of metering pump after routing. Pin assignment is not relevant. 1 Connector housing 2 Lock 3 Blue/brown (bl / br) wires 4 Coding 5 Time lock Remove connector Route fuel line 4 and wiring harness of meter- ing pump 2 in the 1130 mm corrugated tube in the engine compartment, on the frame side member of the firewall and further to the un- derbody. 1 Cable tie 3 Hose section, 10 mm dia. clamp [2x] Connect- ing heater Route fuel line and wiring harness of meter- ing pump 1 in the 2100 mm corrugated tube along the original vehicle lines to the installa- tion location of the metering pump.

Installing lines 28 1 4 2 3 5 5 29 1 4 3 2 30 1 1

Suzuki Swift 1316728A_EN 18 Replace original vehicle bolt at Position 3 with M6x25 bolt. Align bracket of handbrake cable 4 downwards. 1 Metering pump mounting 2 Metering pump Installing metering pump 1 Wiring harness of metering pump, connec- tor installed 2 Hose section, 10 mm dia. clamp [2x] 3 Fuel line of heater Connect- ing meter- ing pump Remove and dismantle fuel-tank sending unit 1 in accordance with manufacturer's instruc- tions. 2 M6 flanged nut 3 Copy hole pattern, 6 mm dia. hole Removing fuel Shape fuel standpipe 1 according to tem- plate, cut to length and install. Installing fuel stand- pipe 31 1 3 2 4 32 1 2 3 33 3 1 2 34 1 1

Suzuki Swift 1316728A_EN 19 Install fuel-tank sending unit 4 in accordance with manufacturer's instructions. 3.5 mm dia., 90° moulded hose 1 on fuel standpipe 5. 2 10 mm dia. clamp 3 Fuel line 6 9 mm dia. clamp Connect- ing fuel line 1 Fuel line 2 Cable tie Routing fuel line Install tank according to manufacturer's in- structions. Check the position of the compo- nents; adjust if necessary. Check that they have freedom of movement. 1 Hose section, 10 mm dia. clamp [2x] 2 Fuel line of fuel standpipe Connect- ing meter- ing pump 35 1 2 5 3 4 6 36 1 2 2 2 1 37 2 1

Suzuki Swift 1316728A_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 not designated connecting spring clips = 25 mm dia. 1 = Black (sw) rubber isolator . All connecting pipes = 18x18 mm dia. Connecting pipe = 18x20 mm dia. B A C D E F G 1 Ø 27 Ø 27

Suzuki Swift 1316728A_EN 21 1 180°, 20 mm dia. moulded hose Shorten- ing Hose A Detach retaining clip of original vehicle wiring harness 1 at Position 3 and insert it at Posi- tion 2 2 Existing hole 3 M6x12 bolt, flanged nut, existing hole 4 Angle bracket Installing angle bracket 1 M6x25 bolt, large diameter washer, flang- ed nut 2 Circulating pump mounting 3 Circulating pump Installing circulating pump 1 Mount wiring harness of circulating pump Connect- ing circu- lating pump 20 1 38 3 4 1 39 2 2 1 3 40 1 B D 1 41 C

Suzuki Swift 1316728A_EN 22 Route hose B and G to the cutting point 1 Cable tie Routing in engine compart- ment Remove hose of engine outlet / heat ex- changer inlet 1 and discard.

Spring clips will not be reused. Cutting point Install hoseA with shortened side on connec- tion piece of engine outlet Connect- ing engine outlet Slide black (sw) rubber isolator 2 onto hose B and align to hose A. Ensure sufficient dis- tance to neighbouring components. 1 Pipe on heat exchanger inlet Connect- ing heat exchanger inlet 42 1 G B G 1 43 1 44 A B 45 2 1 B A

Suzuki Swift 1316728A_EN 23 Combustion air Discard section X 1 Combustion air pipe a = 230 Cutting combus- tion air pipe to length 1 Wheel-well inner panel 2 6 mm dia. hole Hole in wheel-well inner panel 1 Retaining clip in hole Inserting retaining clip 1 Combustion air pipe 2 Silencer in retaining clip 3 25 mm dia. clamp Installing silencer a 1 X 46 1 2 40 47 1 48 1 2 3

Suzuki Swift 1316728A_EN 24 Exhaust gas Discard section X 1 Exhaust pipe a = 330 2 Exhaust end section b = 150 Preparing exhaust pipe 1 Perforated bracket A Angling down per- forated bracket A 1 Perforated bracket B Angling down per- forated bracket B 1 9.1 mm dia.

hole; rivet nuts 2 7 mm dia. hole Installing rivet nut a b 1 2 X 65 55 40° 1 88 70 70° 1 49 1 2 20 20 12

Suzuki Swift 1316728A_EN 25 Cut out underride protection1 at the marking. 2 Discard section Cutting out underride protection 1 Install M6x20 bolt, spring lockwasher loosely 2 M6x20 bolt, large diameter washer, flang- ed nut 3 Perforated bracket A 4 Perforated bracket B Installing performat- ed brack- ets 1 Silencer 2 Perforated bracket A 3 M6x16 bolt, spring lockwasher Installing silencer 1 Hose clamp [2x] 2 Exhaust pipe Installing exhaust pipe 50 1 2 51 3 1 2 4 52 1 2 3 2 1 1 53

Suzuki Swift 1316728A_EN 26 Align exhaust pipe 1. Ensure sufficient dis- tance to wheel-well inner panel at Position 2 and 3, min.

20 mm Aligning exhaust pipe Align exhaust end section 4and position it in the recess at the centre of the underride pro- tection, bend perforated bracket B further down if necessary. Tighten bolt at Position 2. 1 M6x20 bolt, pipe clamp, flanged nut 3 Hose clamp Installing exhaust end sec- tion Align exhaust end section 1 flush to underride protection. Ensure sufficient distance to neighbouring components.

Aligning exhaust end sec- tion 54 1 2 3 1 2 4 3 55 1 56

Suzuki Swift Printed in Germany 06/2011 Printing: Steffen 27 1316728A_EN Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78 (14 Cent aus dem deutschen Festnetz) Hotfax: 0395 5592 353 Hotmail: technikcenter@webasto.com http://www.webasto.com Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Secure all loose wires using cable ties. Only use manufacturer-approved coolant.

Spray the heater components with anti-corrosion wax (Tectyl 100K, Order No. 111329).

- Connect the battery. - Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications. - Set the digital timer. - Make settings on A/C control panel according to the "Operating Instructions for End Cus- tomer". - Place sticker "Switch off parking heater before refilling" in the area of the filler neck - For initial start up and function check, see installation instructions

Suzuki Swift 1316728A_EN 28 Template for Fuel Standpipe 100 mm 100 mm 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 “minimise mar- gins” and 100% of the normal size.

Suzuki Swift 1316728A_EN 29 Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min. In vehicles with passenger compartment monitoring it must be deactivated additionally, besides deac- tivating the vehicle settings for the heating operation. Instructions on deactivation can be taken from the operating instructions of the vehicle Before parking the vehicle, make the following settings: 1 Air outlet to windscreen 2 Set temperature to "max." 3 Set fan to Level "1" or max.

"2" Manual A/C 1 Air outlet to windscreen 2 Set temperature to "HI" 3 Set fan to Level "3" or max. "4" Automatic air-condi- tioning 57 1 3 2 58 3 1 2