BlueHeat Coolant Heater
Thermo Top
Legend
1 BlueHeat Coolant Heater, Exhaust Muffler, and Combustion Air Intake Silencer
2 Fuse Holder and Resistor
3 Timer Control
4 Fuel Pump
Special Tools
– Hose Clamping pliers
– Torque Wrench (1/4' Drive)
Table of Contents
1 2 3 4
Buick Rainier - 2004
Chevrolet Trailblazer - 2002/2004
GMC Envoy (All Models) - 2002/2004
Oldsmobile Bravada - 2002/2003
Special instructions for these models
Part locations may differ slightly dependent on
the vehicle model.
Foreword
Parts List 3
Vehicle Information 3
Scope and Purpose 3
Symbol Identification 4
General References 5
Preparations 5
Heater Installation Site 5
Installation
Electrical - Overview 6
Electrical Harness 7
Timer Control 8
HVAC Harness Connections 9
Integration into Fuel System 10
Heater Preparation and Installation 13
Exhaust Routing and Installation 14
Integration into Coolant System 15
Power/Ground Connection 17
Concluding Work 17
Final Inspection and Start-up 18
Heater Lockout Reset Procedure 19
Wiring Schematics 20
Heater Plumbing Schematic - Inline Method 22
DOC. P/N 5000867A KIT P/N 5000869B Printed in USA Webasto Product N.A., Inc.
– Improper installation or repair of Webasto heating and cooling systems can cause
fire or the leakage of deadly carbon monoxide leading to serious injury or death.
– Installation and repair of Webasto heating and cooling systems requires special
Webasto training, technical information, special tools and special equipment.
– NEVER attempt to install or repair Webasto heating or cooling system unless you
have successfully completed the factory training course and have the technical skills,
technical information, tools and equipment required to properly complete the
necessary procedures.
– ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
– Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel.
3
GM SUV (Mid Size) BlueHeatTM
Foreword
Parts List
Vehicle Information
This installation requires special expertise from a Webasto training course to install a Webasto Thermo Top C/Z,
which means that it may only be installed by a specially trained workshop or dealership. Webasto cannot
accept any liability for faults and damage caused by the system being installed by untrained personnel.
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 C/Z and BlueHeat Coolant Heaters.
These non-binding installation instructions apply to the vehicles listed on the front cover of this installation
document 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 C/Z must be followed. Acknowledged engineering conventions must be
observed for the installation work.
CAUTION
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.
ATTENTION
All relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary
heating devices must be observed!
Quantity Part Part Number
1 Heater Kit 5000516C
1 Installation Kit 5000869B
Manufacturer Model Year Engine Type
Buick Rainier 2004 All
Chevrolet Trailblazer 2002/2004 All
GMC Envoy 2002/2004 All
Oldsmobile Bravada 2002/2003 All
4
BlueHeatTM GM SUV (Mid Size)
Symbol Identification
Symbols that define sections in manual
Mechanical Preparation
Electrical
Coolant
General Symbol Descriptions
Warning
Caution
Flammable or Combustible
Fuel
Exhaust
Combustion Air Intake
Refer to Webasto or Manufacturer Manual
Attention
Part Location on Vehicle
GM SUV (Mid Size) BlueHeatTM
5
General References
– Bare body parts, for example around drilled
holes, must be treated with anti-corrosive
coating.
– Secure hoses, cables and wiring harnesses
with cable ties and fit protective hoses around
them at chafing points.
– Fit edge protectors (opened fuel hose) to
sharp edges.
Preparation
Heater Kit
– Verify and identify all contents of kit.
Vehicle
– Verify fuel content in tank.
CAUTION
For reasons of safety due to the possibility of
fuel spillage during the installation of a fuel
standpipe, it is recommended there be no more
than 1/4 tank of fuel present. If fuel quantity is
greater than 1/4 of capacity, make provisions to
reduce quantity of fuel.
source: http://www.techwebasto.com/heater_ma...s/5000867A.pdf
Thermo Top
Legend
1 BlueHeat Coolant Heater, Exhaust Muffler, and Combustion Air Intake Silencer
2 Fuse Holder and Resistor
3 Timer Control
4 Fuel Pump
Special Tools
– Hose Clamping pliers
– Torque Wrench (1/4' Drive)
Table of Contents
1 2 3 4
Buick Rainier - 2004
Chevrolet Trailblazer - 2002/2004
GMC Envoy (All Models) - 2002/2004
Oldsmobile Bravada - 2002/2003
Special instructions for these models
Part locations may differ slightly dependent on
the vehicle model.
Foreword
Parts List 3
Vehicle Information 3
Scope and Purpose 3
Symbol Identification 4
General References 5
Preparations 5
Heater Installation Site 5
Installation
Electrical - Overview 6
Electrical Harness 7
Timer Control 8
HVAC Harness Connections 9
Integration into Fuel System 10
Heater Preparation and Installation 13
Exhaust Routing and Installation 14
Integration into Coolant System 15
Power/Ground Connection 17
Concluding Work 17
Final Inspection and Start-up 18
Heater Lockout Reset Procedure 19
Wiring Schematics 20
Heater Plumbing Schematic - Inline Method 22
DOC. P/N 5000867A KIT P/N 5000869B Printed in USA Webasto Product N.A., Inc.
– Improper installation or repair of Webasto heating and cooling systems can cause
fire or the leakage of deadly carbon monoxide leading to serious injury or death.
– Installation and repair of Webasto heating and cooling systems requires special
Webasto training, technical information, special tools and special equipment.
– NEVER attempt to install or repair Webasto heating or cooling system unless you
have successfully completed the factory training course and have the technical skills,
technical information, tools and equipment required to properly complete the
necessary procedures.
– ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
– Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel.
3
GM SUV (Mid Size) BlueHeatTM
Foreword
Parts List
Vehicle Information
This installation requires special expertise from a Webasto training course to install a Webasto Thermo Top C/Z,
which means that it may only be installed by a specially trained workshop or dealership. Webasto cannot
accept any liability for faults and damage caused by the system being installed by untrained personnel.
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 C/Z and BlueHeat Coolant Heaters.
These non-binding installation instructions apply to the vehicles listed on the front cover of this installation
document 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 C/Z must be followed. Acknowledged engineering conventions must be
observed for the installation work.
CAUTION
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.
ATTENTION
All relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary
heating devices must be observed!
Quantity Part Part Number
1 Heater Kit 5000516C
1 Installation Kit 5000869B
Manufacturer Model Year Engine Type
Buick Rainier 2004 All
Chevrolet Trailblazer 2002/2004 All
GMC Envoy 2002/2004 All
Oldsmobile Bravada 2002/2003 All
4
BlueHeatTM GM SUV (Mid Size)
Symbol Identification
Symbols that define sections in manual
Mechanical Preparation
Electrical
Coolant
General Symbol Descriptions
Warning
Caution
Flammable or Combustible
Fuel
Exhaust
Combustion Air Intake
Refer to Webasto or Manufacturer Manual
Attention
Part Location on Vehicle
GM SUV (Mid Size) BlueHeatTM
5
General References
– Bare body parts, for example around drilled
holes, must be treated with anti-corrosive
coating.
– Secure hoses, cables and wiring harnesses
with cable ties and fit protective hoses around
them at chafing points.
– Fit edge protectors (opened fuel hose) to
sharp edges.
Preparation
Heater Kit
– Verify and identify all contents of kit.
Vehicle
– Verify fuel content in tank.
CAUTION
For reasons of safety due to the possibility of
fuel spillage during the installation of a fuel
standpipe, it is recommended there be no more
than 1/4 tank of fuel present. If fuel quantity is
greater than 1/4 of capacity, make provisions to
reduce quantity of fuel.
source: http://www.techwebasto.com/heater_ma...s/5000867A.pdf
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