Dodge Ram 2500 3500...21- Main Power Harness 22- 10 GA Red - Battery Positive 23- 10 GA Brown -...

Dodge Ram 2500 / 35002003 / 2004 - 5.7 Liter Gasoline2003 / 2006 - 5.9 Liter Diesel2007 6.7 Liter Diesel

Installation Instructions

BlueHeat Coolant Heater

DOC P/N 5000681BKIT P/N 5000498C

1 PRELIMINARY INFORMATION BLUEHEAT - DODGE RAM 2500 / 3500

2

Foreword

Scope and Purpose

These non-binding installation instructions are intended to support authorized Webasto trained distributors, dealers andpersonnel in the installation of the Thermo Top BlueHeat coolant heaters.

These non-binding installation instructions apply to the vehicles listed on the front cover of this installation documentunless technical modifications on the vehicle influence the installation, excluding all liability claims. Depending on theversion and equipment in the vehicle, changes may be required to the installation work set out in these installationinstructions. In any event, however, the directives in the “installation manual” and “operating manual” Thermo Top must be followed. The appropriate engineering conventions must be observed for the installation work.

ATTENTION!All relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary

heating devices must be observed!

ForewordScope and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . 2Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Heater Installation Site . . . . . . . . . . . . . . . . . . . . . . 3Vehicle Preparations . . . . . . . . . . . . . . . . . . . . . . . . 3InstallationElectrical Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 4Blower Connection . . . . . . . . . . . . . . . . . . . . . . . . . 6Timer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8Integration into Fuel System . . . . . . . . . . . . . . . . . . 8

Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . .12Integration into Coolant System . . . . . . . . . . . . . . .14Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . .16Power Connection . . . . . . . . . . . . . . . . . . . . . . . . .16Concluding Work . . . . . . . . . . . . . . . . . . . . . . . . . .16Final Inspection and Initial Start-up . . . . . . . . . . . . .17Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .18Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . .20Coolant Schematic . . . . . . . . . . . . . . . . . . . . . . . . .22

Tools Required

1/4” Drive Ratchet1/4” Drive 4 inch extension10 mm six point socket, 1/4” drive10 mm six point deep well socket, 1/4” drive

3/8” Drive Ratchet3/8” Drive 12 inch extension13 mm socket, 3/8” drive15 mm socket, 3/8” drive17 mm socket, 3/8” drive

10 mm combination wrench

8 mm nut driver

Phillips #2 screwdriver

Combination side-cut/crimping pliers

Hose clamping pliersHose cutting pliers

Drill2.5 mm (3/32 in.) drill bit8 mm (5/16 in.) drill bit10 mm (25/64 in.) drill bit

HacksawUtility KnifeMechanic’s wire - 2 feetHoisting equipment and safety standsVehicle manufacturer’s service reference manual

CAUTIONLocation of heater, installation of coolant lines, fuel system and components, wiring and control devices areimportant for proper operation. Failure to comply with the installation instructions provided may result in

poor operation or damage to heater and vehicle components.

Page

Table of Contents

Vehicle Preparations

Heater Kit

1. Verify and identify all contents of kit.

Vehicle

1. Verify fuel content in tank.

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. Remove right front fender splash shield.

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

BLUEHEAT - DODGE RAM 2500 / 3500 1 PRELIMINARY INFORMATION

3

Heater Installation Site

The Webasto auxiliary coolant heater is to be installed on the right frame rail near the front bumper. Refer to Figures 1and 2 for location of heater..

Front

Fig. 1 Fig. 2

CAUTIONFor safety reasons due to weight of fuel and tank, it is recommended there be no more than ¼ tank or lessof fuel present. If fuel quantity is greater than ¼ of capacity, make provisions to reduce quantity of fuel or

consider removal of pick-up box to gain access to fuel sender location if feasible.

2 INSTALLATION BLUEHEAT - DODGE RAM 2500 / 3500

4

Universal Electrical Harness - Description

Legend for Figure 3

1- Fuse Holder and Fuses

2- Resistor - HVAC blower speed control

3- Relay K1 - HVAC control

4- Relay K2 - HVAC control

5- 18 GA Green - ‘ON’ signal from relay K1 and K2 torelay K3, Pin 86 (Use when relay K3 is mountedwith relay K1 and K2)

6- 18 GA Blue - to Ignition ‘ON’ signal source

7- Main Heater Harness - BlueHeat Coolant Heater

8- Blower Control Harness - Positive side

9- 10 GA Red - Connects to HVAC control switchcircuit, positive side, to blower motor

10- 10 GA Black - Connects to HVAC blower motorpositive side

11- 18 GA Green - ‘ON’ signal from relay K1 and K2 torelay K3, pin 86 (Use when relay K3 is mountednear HVAC blower motor - same function as item 5)

12- Blower Control Harness - Negative side(Harness is wire tied to main harness. Cut wire tieand separate from main harness before installing)

13- 10 GA Blue - Connects to HVAC control switchcircuit, negative side, to blower motor

14- 10 GA White - Connects to HVAC blower motornegative side

15- 10 GA Brown - Connects to vehicle ground pointwhen relay K3 is mounted near HVAC blower motor

16- 18 GA Green - Relay K3, pin 86 (Connects to ‘ON’signal 18 GA green from relay K1 and K2).See item 5 and 11.

17- Relay K3 - HVAC control (Typically mounted nearHVAC blower motor)

18- 18 GA Blue & Brown - Fuel Metering Pump Harness

19- 20 GA Black, Red & Brown - Timer Harness

20- 18 GA Violet - “Vent Mode” for optional remote control

21- Main Power Harness

22- 10 GA Red - Battery Positive

23- 10 GA Brown - Battery Negative or Ground Point

24- 18 GA Yellow - Diagnostic Connection

25-18 GA Orange - Supplemental heating option - Not applicable to BlueHeat

26- 10 GA Brown - Optional ground connection for relay K3 when K3 is mounted with relay K1 and K2 (Same functionas item 15)

Fig. 1

8

9

10 11

12

13

1415

1617

18

19

20

26

23

24

25

21

22

12

6

5

7

3

4

Fig. 3

BLUEHEAT - DODGE RAM 2500 / 3500 2 INSTALLATION

5

1

Fig. 4

Installation

– Drill two holes in vehicle bulkhead (1) for mounting the fuse, relay, resistor cluster. Refer to Figure 4.

– Install two relays (3) and resistor (2) on mounting bracket (4) with hardware provided. Refer to Figure 5.

– Install mounting bracket (4) on bulkhead (1) with two M6 capscrews and nuts.

– In this application the fuses were mounted behind the mounting bracket (4) using a nylon wire tie.

Harness Routing

– Route heater control harness (5) to the passenger side of the engine compartment following the vehicle battery cables (6). Route heater control harness (5) down to the heater mountinglocation along the fan shroud (7). Refer to Figure 6.

– Use the existing harness clips and nylon cable ties to secureheater control harness.

NOTE: The timer and blower control harnesses can be routed through unused bulkhead grommets if available, otherwise perform the following step.

– Cut a ½ inch hole in the bulkhead main harness grommet (8).Route timer and blower control harnesses (9) through grommet (8) into the drivers foot-well area. Refer to Figure 7.

Fig. 5

34

2

5

7

Fig. 7

Fig. 6

6

98

Fig. 7


6

– Pull main blower control harness (3) and timer harness (1) through grommet (2) in footwell area. Refer to Figure 8.

– Route main blower control harness (3) under dash to the blower motor (4). The blower motor (4) is located belowthe glove box on the passenger side of the vehicle. Refer toto Figure 9.

Integration into the Blower System

NOTE: It is permissible to cut excess length from blowercontrol wiring harnesses.

– Mount blower control K3 relay (6) with auxiliary blowercontrol harness (5) to vehicle near blower motor (4). Refer to Figure 9.

– Cut auxiliary blower control harness (5) to desired length.

– Crimp connect green wire (9) from main blower harness (3) to green wire pigtail (8) at auxiliary blower control harness (5).Refer to Figure 10.

– Connect brown (ground) wire (7) from auxiliary blower controlharness (5) to a suitable ground point on the vehicle.

– Identify the positive and negative blower control wires (10) connected to the vehicles blower motor (4). Refer to Figure 11.

– Cut both vehicle blower control wires at a point about 50 mm(2 in.) from motor plug and make the connections asdescribed in the following steps. Also, see Figure 14

Fig. 8 3

1

89

3

4

56

7

2

10

4

Fig. 9

Fig. 10

Fig. 11

5


7

Positive blower wire

1. Connect the red wire (3) to the vehicle side of the positive wire (4). Refer to Figure 12.

2. Connect the black wire (2) to the blower motor side of thepositive wire (1).

Negative blower wire

1. Connect the blue wire (7) to the vehicle side of the negativeblower wire (8). Refer to Figure 13.

2. Connect the white wire (6) to the blower motor side of thenegative wire (5).

Legend for Figure 18

A From Webasto Heater X1

B 12 VDC Ignition “On” Fuse Tap

C HVAC Control Module

M HVAC Blower Motor

X Cut wire at 50 mm (2 in.) from motor

F1 Fuse - Blower Circuit 25 Amp

K1 Relay - Ignition “On” Interrupt

K2 Relay - Positive Side of Blower Motor Circuit

K3 Relay - Negative Side of Blower Motor Circuit

R1 Resistor - Blower Speed Control

30 Battery Positive (Constant Power)

15 Ignition (Switched Power)

31 Battery Negative (Chassis Ground)

ATTENTION!Ensure that connections are done correctly. For more detail

of wiring circuits, turn to the back of this manual forcomplete wiring schematics.

Fig. 14

7

58

32

1

4

6

Fig. 12

Fig. 13

Webasto Vehicle


8

Timer Installation (General Instructions)

NOTE: Before installing the timer, please confirm theinstallation site with your customer.

– After selecting a site for the timer, temporarily apply the timermounting template. Refer to Figure 15 for a translated sampleof the template.

– As specified on template, drill the 10 mm (25/64in.) and the2.5 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 timerand push into socket until seated.

– Place the timer (1) into position and secure with screwprovided until the timer with foam cushion is firmly seatedagainst panel. Refer to Figure 16.

– Tighten screw no more than 0.8 Nm (7.0 lb-in.).DO NOT OVER TIGHTEN!

– Refer to Figure 16 for a completed timer (1) installationexample.

Integration into Fuel System

– Follow the manufacturers service procedure to access and remove the fuel sender unit from fuel tank.

Recommended Standpipe Location - 5.9L Diesel(2002-2004)

– Drill a 8.5 mm (21/64 in.) hole (2) through the fuel sender (1)in the location shown in Figure 17.

– To prevent fuel seepage around standpipe, remove burrs fromboth sides of hole (2) after drilling.

Fig. 16: Timer Placement (EXAMPLE ONLY!)

ATTENTION!Before drilling into any panels, ensure there are no hidden

components behind the panel that may be damaged orinterfere with the timer installation!

DO NOT OVER TIGHTEN MOUNTING SCREW!

1

CAUTIONFull to partially filled fuel tanks are heavy and awkward to

handle. If fuel tank removal is necessary to access fuelsender, ensure fuel level is near empty.

To prevent accidents or injury to personnel, make suretank is well supported prior to removing mounting

hardware.

Fig. 15: Timer Template (NOT TO SCALE!)

1

Fig. 17 2

ATTENTION!Ensure standpipe location does not interfere with fuel

sender float movement.


9

Recommended Standpipe Location - 5.9L Diesel(Spacer Required)

– Position the fuel sending unit spacer (3) in the slot identified infigure 18. Use the spacer as a template to mark the hole location for standpipe installation. Remove spacer before drilling hole.

– Drill a 8 mm (5/16 in.) hole (2) through the fuel sender (1)in the location marked.

– To prevent fuel seepage around standpipe, remove burrs fromboth sides of hole (2) after drilling.

– Reinstall spacer (3) into slot in fuel sender (1), ensuring the beveled edge is facing down.

Recommended Standpipe Location - 5.7L Gasoline(HEMI)

– Drill a 8.5 mm (21/64 in.) hole through the fuel sender (1)in a location suitable for standpipe installation. See Figure 19.

– To prevent fuel seepage around standpipe (4), remove burrs from both sides of hole after drilling.

Installing Standpipe with 90 Degree Banjo Fitting

NOTE: Cut standpipe to a length approximately 25 mm(1 in.) from the bottom of the fuel tank with a 45° slash-cut. Remove any burrs after cutting tube.

Do not cut standpipe used for the HEMI applicationat this time. Preview instructions on page 10 beforeproceeding.

– Cut standpipe (4) to length (approximately 13.5 in.) and bend if necessary to clear any fuel sender components.

– Place one sealing washer (7) on standpipe (4) and insertstandpipe (4) through drilled hole. See Figure 20.

– Place remaining sealing washer(7) on standpipe fromunderside. Secure standpipe (4) with lock nut (9). Tighten lock nut to a torque of 9 ± 0.5 Nm. (80 ± 4.4 lb-in.).

– If necessary, to reposition banjo fitting (6) outlet, loosenbanjo bolt (5) to allow movement. Banjo outlet should run inthe same direction as the other fuel outlet pipes.

– Tighten banjo bolt to a torque of 9 ± 0.5 Nm. (80 ± 4.4 lb-in.)after repositioning outlet.

Fig. 18

5

6

4

7

8

7

9

Fig. 20

Fig. 19

2

3

1

1

4

Legend for Figure 205 Banjo Bolt6 Banjo Fitting - 90 Degree4 Standpipe7 Sealing Washer8 Fuel Tank or Sender Plate9 Lock Nut


10

Fuel Standpipe Instructions - 3500 (HEMI)

– Bend standpipe (1) 90 degrees as shown in Figure 21.

NOTE: Use the slotted tube molded into the side of the sending unit to secure the standpipe away from the fuel level float.

– Insert standpipe (1) into slotted tube (3) in fuel sender (2) as shown in Figure 22.

– Fully extend fuel sender (2). Mark standpipe (1) length to approximately 25 mm (1 in.) from bottom of fuel sender (2).

– Collapse fuel sender (2) and cut off excess standpipe (1) where marked. The overall length of the standpipe (1), after the bend, is 34 cm (13.5 in.).

Connecting Fuel Line to Outlet Fitting - All

– Install fuel sender unit (2) according to the vehicle manufacturers service procedures.

– Align outlet fitting (4) with vehicle fuel lines, as shown in Figure 23.

– Install rubber fuel line connector (7) on fuel standpipe banjooutlet nipple and secure with clamp (8).

– Place clamp (6) over rubber connector and insert plastic fuelline (5) into connector until it bottoms out against nipple. Secure with clamp (6) as shown in Figure 23.

– Observe Figure 24 for correct fuel line connecting.

– Cover the fuel line (5) with conduit and snap into moldedhold down on the fuel tank. Refer to Figure 23.

– If fuel tank was removed to gain access to sender, install tankaccording to manufacturers service procedures.

27

5

6

Fig. 23

4

Fig. 21

Fig. 22

Fig. 24

1

3

1

2

8


11

Fuel Pump Installation - Diesel

– Install fuel pump (5) on vehicle frame with hardware provided in kit. Refer to Figure 25 for mounting location.

– Install rubber fuel line adapter (3) on inlet side of fuel pump (5) and secure with clamp (4).

– Insert fuel line (1) into rubber fuel line adapter (3) until it bottoms out against nipple and secure with clamp (2).

– Install rubber fuel line adapter (8) on outlet side of fuel pump (5) and secure with clamp (7). Refer to Figure 26.

– Insert fuel line (10) into rubber fuel line adapter (8) until it bottoms out against nipple and secure with clamp (9).

– Route fuel pump harness (6) to fuel pump (5) following vehicle brake/fuel lines and connect to fuel pump (5)

– Cover the fuel line (10) with black conduit. Route the fuel line (10) with the vehicles fuel lines (11) to the underhood compartment. Refer to Figure 27.

Fuel Pump Installation - RAM 3500 (HEMI)

– The fuel pump (12) for the HEMI application is located above the fuel tank on the frame as shown in Figure 28.

– Follow the instructions above for fuel pump installation.

Front

6 75 8 9 10

Fig. 26

Fig. 28

Front

21 3 4 5

Fig. 25Front

Front

10

Fig. 27

11

12


12

– Route the fuel line (1) along fuel pump harness (2) and vehicle lines toward the engine compartment. Refer to Figure 29.

– Use nylon wire ties to secure fuel line (1) and fuel pump harness (2) to frame rail. Refer to Figure 30.

– Route the fuel line (1) along heater control harness (3),across radiator, to the heater mounting location. Refer to Figure 31.

– Secure fuel line (1) to the heater control harness (3) using nylon wire ties.

Heater Installation

– Install EJOT stud (7) with M6 washer before installing heater mounting bracket (5) on heater. See Figures 32 and 35.

– Install heater mounting bracket (5) on heater with two EJOT screws (4).

– Install heater support bracket (6) on EJOT stud (7) with nut provided. Do not tighten nut until heater is installed on frame.

3

1

Fig. 31

CAUTIONEnsure fuel line is secured away from hot exhaust

components.

Front

Fig. 30

Fig. 29

1

2

1 2

ATTENTION!Some preassembly of the heater is necessary before

installing. The next steps will detail the installation of themounting bracket and the combustion air intake tube.

4

Fig. 32

5

7

6


13

– Remove knock out from top of heater (5) and install the combustion air silencer clamp (3). Refer to Figure 33.

– Install combustion air intake tube (2) on heater and secure with clamp (1).

– Thread combustion air silencer (4) into combustion air tube (2).

– Secure combustion air silencer (4) to top of heater (5) with previously installed clamp (3).

– Remove right front wheel well splash shield to gain access to installation site (7).

– Prepare installation site (7) by cutting away the lower section of the right front spalsh shield (6) (if equipped). See Figure 34.

– Refer to Figure 35 for an overview of how the Webasto heateris installed.

– Install the heater mounting bracket (8) on vehicle frame rail (9) with two bolts (12), spacers (11), rear strap, and two nuts (10). Refer to Figures 35 and 36.

Fig. 34

10

12

Fig. 369

8

11

Fig. 35

2

3

45

1

Fig. 33

6

7


14

– Secure heater support bracket (3) to the frame / bumper mounting bolt with nut (2) provided. Refer to Figure 37.

– Tighten nut securing heater support bracket (3) to EJOTstud(1).

Fuel and Electrical Connections at Heater

– Connect heater control harness (4) to the heater. Refer to Figure 38.

– Pre-assemble rubber fuel line adapter (6) with two clamps.

– Install rubber fuel line adapter (6) on heater and secure with clamp (7).

– Insert fuel line (8) into rubber adapter (6) until it bottoms out against the fuel inlet nipple and tighten clamp (5).

Integration into Coolant System - Diesel

– Cut the two formed coolant hoses found in kit to 1.54m (5 foot) sections. Cut the 180 degree end to 90 degrees onboth hoses.

– Cover both hoses with black conduit before installing.

– Connect 90 degree end of heater inlet hose (11) and heater outlet hose (9) to heater and tighten hose clamps (10). See Figure 39.

– Route heater coolant hoses (9) and (11) as shown in Figure 40.

– Secure coolant hoses (9) and (11) using nylon cable ties.

Fig. 37

1

32

Fig. 38

CAUTION!Ensure coolant lines are secured away from all suspension

parts and heat sources!

10

Fig. 39

11

9

Fig. 40

5

8 7

4

6

9

11 10


15

– To prevent coolant loss, clamp off coolant hose (1) going to heater core. See Figure 41.

– Cut vehicle coolant hose (1) coming from engine block (2) in two places.

– Connect heater inlet hose (3) to coolant hose (1) from engine block with coupler (5) and two hose clamps (4). See Figure 42.

– Connect heater outlet hose (8) to heater core inlet hose with 90 degree coupler (6) and two hose clamps (7).

Integration into Coolant System - HEMI

– Cut the two formed coolant hoses found in kit to 1.54m (5 foot) sections. Cut the 180 degree end to 90 degrees onboth hoses.

– Cover both hoses with black conduit before installing.

– Route Webasto heater coolant hoses (13) and (15) along passenger inner fender well. Refer to Figure 43.

– Cut 90 degree bend from the heater core coolant hose (11) coming from the engine as shown in figure 43.

– Connect Webasto heater inlet hose (13) to heater core coolanthose (11) using 90 degree copper reducer (14) and two hose clamps (12).

– Disconnect OEM heater core coolant hose at connection prior to the heater core. Discard OEM section of hose, adapter, and constant pressure clamp.

– Connect Webasto heater coolant outlet hose (15) to heater core coolant hose (9) using adapter/reducer and two hose clamps (10). Refer to Figure 43.

Coolant Line Connections at Heater

– Connect coolant inlet hose (13) from engine block to the Webasto heater circulation pump (17) and tighten clamp (18).Refer to Figure 44.

– Connect coolant outlet hose (15) from heater core to coolant outlet on the Webasto heater and tighten clamp (16).

15

13

ATTENTION!Torque all hose clamps to 1.7 Nm (15 lb-in.).

Fig. 44

17

2

CUT

Fig. 41

ATTENTION!Removal of the air cleaner assembly will provide greater

access to the inner fender well area.

ATTENTION!Torque all hose clamps to 1.7 Nm (15 lb-in.).

13

10

Fig. 43

11

12

14

15

9

1

3 1

68

5

7

4

Fig. 42

16

18


16

Exhaust

– Install 90 degree exhaust elbow (5) onto heater (1) and securewith clamp (6). Refer to Figure 45.

– Cut exhaust tube (3) to a length of 22.8cm (9 inches).

– Connect exhaust tube (3) to 90 degree elbow (5) and secure with clamp (4).

– Secure exhaust tube (3) to heater mounting bracket with clamp (2).

– Bend exhaust tube (3) 90 degrees so it faces to the rear of the vehicle and down.

Fuse Tap Connection - Relay K1

– Route the blue fuse tap wire (9) to fuse panel (7) as shown inFigure 46.

– With a test light, find an “Ignition ON” power source. Testlight must be off when ignition key is in the OFF position.

– Using the supplied fuse tap connector, tap into the “fused”side of the selected fuse (8) as shown in Figure 46.

Power Connection

– Connect red power lead (10) to existing stud (11) in front of fuse block (7) as shown in Figure 47.

Concluding Work

– Install all vehicle parts, panels and components removedduring heater installation.

– Check that all hose lines, hose clamps and pipe clips and allelectrical connections are secure.

– Secure all loose lines and cables with nylon cable ties

– Spray the heater components and electrical connections withan anti-corrosive wax coating.

– Turn to “Final Inspection” and “Initial Start-up.”

Fig. 45

Fig. 46

Fig. 47

5

411

1

6

42

987

11

107

3


17

Final Inspection and Initial Start-up

Final Inspection

Inspect installation for:• loose fasteners.• exhaust system routing and clamp tightness.• combustion air intake tube routing and clamp tightness.• loose coolant line clamps.• pinched coolant lines.• routing of coolant lines and coolant lines securely tied and protected against chaffing and related damage.• loose fuel line clamps.• routing of fuel lines and fuel lines securely tied and protected against chaffing and related damage.• loose wiring connections and battery connections.• routing of wiring harness and wiring harness securely tied and protected against chaffing and related damage.• check operation of vehicle heater fan with Webasto heater OFF.

Initial Start-up

1. Top off cooling system with coolant per engine/vehicle manufacturers recommendations.

2. Set interior heater control to maximum heat position (hot) and switch off air conditioning system.

3. Start the vehicle engine and run on fast idle for 5 minutes to purge any remaining air from the Webasto heater andcoolant system. While the engine is running check:

• hose connections for leaks.• coolant level in expansion tank. Add coolant as needed.

4. Switch off the engine.

ATTENTION!Coolant temperature must be below 30 °C (86 °F) before heater will attempt to start.

ATTENTION!More than one start-up attempt of the heater may be required to purge air from fuel system before heaterwill start. Cycle heater Off and On after each failed start attempt until heater starts successfully. No further

start attempts are possible until the control unit lockout condition is cleared.

ATTENTION!Engine coolant temperature gauge may read lower than actual Webasto heater output temperature. This is

due to the location of the temperature gauge sensor on engine.

5. Switch on the Webasto heater by means of the instant heat button on timer and check:

• timer panel and instant heat indicator illuminates.• circulating pump in operation.• initiation of start-up sequence.• successful start-up and operation.

6. Allow heater to run for 20 minutes or until coolant is heated to temperature. Re-tighten all hose clamps.


18

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 information on defective wiringand connections.

Should the heater not function after completing the installation and initial start-up instructions, refer to the followingtroubleshooting instructions and information to isolate and remedy the cause for malfunction.

In the event you are unable to remedy a malfunction after following these troubleshooting instructions or forunanticipated malfunctions beyond what is covered in this troubleshooting section, please contact one of our WebastoTechnical Assistance Representatives for further instructions.

In the USA, call (800) 555-4518In Canada, call (800) 667-8900

CAUTIONTroubleshooting requires comprehensive knowledge about structure and theory of operation of the heater

components and may only be performed by Webasto trained and certified, professionals.

Before troubleshooting, check for and eliminate the following probable causes for trouble:

• power supply to heater is less than 10.5 volts at main power connections (charge batteries and perform load test).• blown fuses.• corrosion on battery terminals for heater, electrical wiring, connections and fuses.• loose contacts or connectors, wrong crimping on connectors.• ensure heater and components have been correctly installed following all pertaining installation instructions.• shut down initiated by temperature limiter.• heater control unit locked out. Refer to “Heater Lockout Reset Procedure.”

ATTENTION!After correction of a malfunction, a functional test has to be performed with heater installed on the vehicle.

Basic Troubleshooting

3.2 Heater Lockout Reset Procedure

The BlueHeat is designed with a lockout safety feature built in to the control unit. After 3 consecutive unsuccessfulstartup attempts, the heater will lock itself out from any further start attempts. The heater may also enter the lockoutmode after experiencing an overheat condition.

Before troubleshooting the heater, ensure heater is not in the “Lockout” mode by performing the following resetprocedure:

1. Ensure timer or switch is in the off position. Turn timer or switch to the on position. Remove main fuse F2 (20 Amp),Reinsert after 5 seconds.

2. Cycle timer or switch off and then back on once more. Remove fuse F2 once again and reinsert after 5 seconds.Heater should attempt to start in 10 seconds after inserting fuse.

ATTENTION!Coolant must be below 60 °C (140 °F) before heater will attempt to start.


19

CAUTIONDiagnostics 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 more thorough testing and troubleshooting ofthe heater and its components beyond the scope of this installation manual. The diagnostic kit makes it possible to readand remove (reset) stored malfunction codes from the BlueHeat memory.

The PC Diagnostic Interface Kit comes complete with connecting hardware, software and instructions for use with anyIBM/PC compatible computer. Also available are several interface connectors for use with Webasto heaters equipped withinternal diagnostic capabilities such as the BlueHeat.

In addition to working with stored malfunction codes, the PC Diagnostics Interface Kit allows you to perform severalother functions such as reading values while the heater is in operation or testing individual components. Printing outmalfunction codes is also available (User supplied printer required).

For further capabilities and instructions for use with the BlueHeat heater, see the instruction manual supplied with the PCDiagnostics Interface Kit.

Order PC Diagnostics Interface Kit under part number 92542F. Kit does not include required adapter for the BlueHeatand must be included in your order. Order adapter under part number 92566A.

PC Diagnostics Interface Kit

General Malfunction Symptoms

The following table lists possible malfunction symptoms.

Malfunction Symptom

Coolant heaterswitches offautomatically(Fault lockout)

Heater expels blackfumes from exhaust

Probable Cause

No combustion after startor automatic repeat start

Flame extinguishes duringoperation

Heater overheats

Vehicle electrical systemvoltage too low

Combustion air and/orexhaust ducting blocked

Remedy

Switch off heater momentarily and switch on once again

Switch off heater momentarily and switch on once again

Check coolant lines for obstructions, closed valves and kinks.Check coolant level. Allow heater to cool down, reset overheatlimiter, switch off heater momentarily and switch on once again

Charge batterySwitch off heater momentarily and switch on once again

Check combustion and exhaust ducting for obstructions

Table 1: General Malfunction Symptoms


20

Heater Harness Schematic - Heater Control Portion


21

Heater Harness Schematic - Blower Control Portion


22

Heater Plumbing Schematic - Inline Method

Webasto Product N.A., Inc.Technical Assistance HotlineUSA: (800) 555-4518Canada: (800) 667-8900

www.webasto.uswww.techwebasto.comOrg. 10/2002 Rev. 10/2004 P/N 5000681B

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