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DOC P/N 5001336B KIT P/N 5001335C Printed in USA Webasto Product N.A., Inc.

BlueHeat Coolant Heater

Thermo Top

Special Tools– Hose Clamping pliers – Torque Wrench

Table of Contents

Ford F-250/350 Super Duty6.4 Liter TT Diesel6.8 Liter V10 GasolineBeginning Model Year: 2008

Special instructions for these modelsPart locations may differ slightly dependent on the vehicle model.

ForewordParts List 3Vehicle Information 3Scope and Purpose 3Symbol Identification 4General References 5Preparation 5Heater Installation Site 5

InstallationElectrical - Overview 6Electrical Harness Installation 7Timer Installation 7Fuse Tap Connection - Relay K-1 8Integration into the Blower System 83-Relay HVAC Harness Connections 9K3 Relay Ground 10Heater Control and Fuel Pump Harness Routing 10Heater Preparation and Installation 11Heater Mounting 11Exhaust Installation 12Integration into the Coolant System - 6.4 Liter TT Diesel 13

Coolant Hose Connections - 6.4 Liter TT Diesel 14Integration into the Coolant System - 6.8 Liter V10 Gasoline 15Coolant Hose Connections - 6.8 Liter V10 Gasoline 16Combustion Air Intake Installation 18Integration into the Fuel System 19Fuel Pump Installation 19Fuel Line and Fuel Pump Harness Routing 20Standpipe Installation - 6.4 Liter TT Diesel 21Standpipe Installation - 6.8 Liter V10 Gasoline 22Power Connection 24Ground Connection 24Final Inspection, Initial Start-up and Concluding Work 25Heater Lockout Reset Procedure 26Electrical Harness Schematic - Part 1 27Electrical Harness Schematic - Part 2 28Heater Plumbing Schematic - Inline Method 29

Warning• 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 spe-cial Webasto training, technical information, special tools and special equip-ment.

• NEVER attempt to install or repair a 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 prop-erly 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 or by improper installation.

• Improper installation or installation by untrained personnel voids all warranties on this product.

If there are any questions regarding the installation or maintenance of this product,please call technical support at 1-800-555-4518.

3

Ford F-250/350 Super Duty Truck BlueHeatTM

Parts List

Vehicle Information

ForewordThe installation and service of Webasto Thermo Top series (BlueHeat) heaters requires special expertise and training. Installations and servicing of Webasto products by untrained, unauthorized personnel and end-users voids all warranties and releases Webasto Product North America, Inc. and Webasto authorized distributors, dealers and their personnel from responsibility for damage to Webasto products, 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 products. The same applies for repairs without using genuine Webasto service parts. This will void the coolant heaters “official Marks of Conformity.”

Scope and PurposeThese installation instructions are intended to support Webasto trained and authorized distributors and dealers in the installation of the Thermo Top series (BlueHeat) Coolant Heaters. These instructions are not intended for use by untrained or unauthorized personnel.

The directives in the “installation manual” and “operating manual” for the Thermo Top series heater must be followed. Acknowledged engineering conventions must be observed for the installation work.

ATTENTIONAll relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary heating devices must be observed!

CAUTIONLocation 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.

Quantity Part Part Number

1 Heater Kit - 6.4 L Dieselor

Heater Kit - 6.8 L Gasoline

5001325A

5000516C

1 Installation Kit 5001335C

Manufacturer Model Year Engine Type

Ford F-250/350 Super Duty Beginning Model Year: 2008

6.4 Liter Diesel and

6.8 Liter Gasoline

4

BlueHeatTM Ford F-250/350 Super Duty Truck

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

Line of Sight/Item Location on Vehicle

Ford F-250/350 Super Duty Truck

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 weight of fuel and the tank, it is recommended that 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 or consider removal of pick-up box to gain access to fuel sender.

– Disconnect negative terminal of vehicle battery(s).– Remove Air Cleaner Assembly– Remove instrument panel cover for timer mounting. Refer to vehicle manufacturers instructions.– Protect vehicle fenders, panels and interior with covers

Heater Installation Site

Mount the Webasto auxiliary heater under the right side of the cab, behind the front tire.

– (1) Webasto auxiliary coolant heater (Installed)– (2) Right-front running board bracket

1

Fig. 1

2

BlueHeatTM

6


Electrical - Overview

ATTENTIONIf not described differently, secure wiring and cables with cable ties to the vehicle’s own wires and cable harnesses.

ATTENTIONTimer control location is a recommendation only. Please consult with the customer before mounting.

HVAC Blower Motor Fuel Metering Pump(1) Blower Motor (1) Right Framerail

(2) Fuel Pump

Fuse Block/Relays/Resistor Timer Control(1) Relays K1 & K2 (1) Digital Timer(2) Fuse Holder

1 21

1

2

1


7

Electrical Harness InstallationATTENTIONModify electrical mounting bracket as shown in Figure 2.

Cut wire tie holding negative-side blower harness (with relay) from main harness and set aside.

Install resistor and relays on electrical mounting bracket.

– (1) Mounting bracket– (2) Resistor– (3) Screw M3x10, Nut M3 (2 ea.)– (4) Pan head screw 10-32x5/8”, Nut 10-32 (2 ea.)– (5) Relays K1 and K2

Secure the electrical mounting bracket assembly to the bulkhead using a self-tapping screw.

– (1) Vehicle bulkhead - left corner– (2) Electrical mounting bracket assembly

CAUTIONUse care when cutting bulkhead grommet to prevent damage to vehicle electrical harnesses.

Cut a 12.7 mm (.5 inch) slit in the bulkhead pass-through grommet.

Route the timer and blower control harnesses into the interior of the vehicle through the bulkhead grommet.

Timer InstallationCAUTIONCheck behind panels for obstructions before drilling holes.

ATTENTIONBefore installing the timer, please confirm the installation location with the customer.

Affix supplied template to panel. Drill 10 mm (25/64 in.) and 2.5 mm (3/32 in.) holes where indicated on template. Figure 5 shows a translated sample of the template supplied.

3

Fig. 2

4

21

5

Fig. 3

21

Fig. 4

IMAGE NOT AVAILABLE

Fig. 5

8


– (1) Timer - recommended location only

Fuse Tap Connection - Relay K-1CAUTIONTap into the “fused” output side of the selected fuse.

Locate a fuse (10 to 20 amp) in the fuse / relay center that is “HOT” when the ignition is in the ON position only.

Route blue fuse tap wire from relay K-1 to the fuse /relay center.

– (1) Underhood fuse / relay center– (2) Fuse tap

ATTENTIONThe underhood fuse / relay center cover has to be modified slightly to close properly after installing the fuse tap.

Modify cover in locations circled in Figure 8.

– (1) Underhood fuse / relay cover

Integration into the Blower SystemRoute Blower harness over to blower area.

Mount negative-side blower harness and relay in vicinity of HVAC blower.

Wire according to schematic in Figure 10.

– (1) Relay K3 – (2) Blower motor connector– (3) Blower power wire– (4) Blower ground wire

Fig. 6

1

1

Fig. 7

26.8 liter V 10

Fuse For

Fig. 8

1

1

2

Fig. 9

34


9

3-Relay HVAC Harness ConnectionsNOTE:It is permissible to cut excess length from Webasto HVAC wiring harnesses to fit the application.

Cut motor wires where indicated by “X”

– (1) Chassis ground– (2) Splice green wire to green wire – (3) Strip and crimp red to controller side power wire– (4) Strip and crimp black to motor side power wire– (5) Strip and crimp white to motor side ground wire– (6) Strip and crimp blue to controller side ground wire

CAUTIONCheck your wiring! Ensure that all connections have been done in accordance with the wiring diagram shown (Fig. 10). Sensitive electronic controls can be damaged if wired incorrectly!

Secure HVAC blower control wiring to vehicle structures with nylon wire ties. (Image not available)

NOTE:Complete heater harness schematics are included on page 27 and 28 of this manual.

2

1

6

5

4

3

Webasto Vehicle

Fig. 10

YL/GN

YL/GN

PL/PK

PL/PK

K2 Relay - Positive Side of Blower MotorK3 Relay - Negative Side of Blower Motor R1 Resistor - Blower Speed Control30 Battery Positive (Constant Power)15 Ignition (Switched Power)31 Battery Negative (Chassis Ground)

Legend for Figure 10A From Webasto Heater X1B 12 VDC Ignition ‘On’ Fuse TapC HVAC Control ModuleM HVAC Blower MotorX Cut wire at 50 mm (2 in.) from motorF1 Fuse - Blower Circuit 25 Amp.K1 Relay - Ignition ‘On’ Interrupt

10


K3 Relay GroundSecure K3 Relay ground wire to a known good chassis ground.

– (1) K3 relay ground– (2) A-pillar (right-side)

Heater Control and Fuel Pump Harness Routing

CAUTIONSecure heater control and fuel pump harnesses away from hot exhaust components and moving vehicle components with cable ties.

Route the heater control and fuel pump harnesses under the engine to the right side of the vehicle.

– (1) Heater control and fuel pump harnesses– (2) Engine oil pan

Secure the heater control and fuel pump harnesses to the engine cradle with cable ties. See Figure 13.

– (1) Engine oil pan– (2) Engine cradle– (3) Heater control and fuel pump harnesses

Route the heater control and fuel pump harnesses over the right framerail where shown in Figure 14.

– (1) Heater control and fuel pump harnesses– (2) Right framerail

ATTENTIONThe remainder of the fuel pump harness will be routed later in this manual.

1

2

Fig. 11

Fig. 12

2

1

Fig. 13

21 3

Fig. 14

21


11

Heater Preparation and Installation

ATTENTIONObserve torque specifications.

Install heater mounting bracket on heater.

– (1) Heater mounting bracket– (2) M6 EJOT screw (3 ea.) Torque 10 Nm (88.5 lb-in.)

ATTENTIONIf the vehicle is not equipped with running boards, install panel nuts provided using the existing holes in the cab.

Position the heater in it’s mounting location.Align the holes in the rear of the mounting bracket with the panel nuts previously installed or existing hardware used to secure running boards and mark the front mounting hole location on the cab.Set heater aside and drill the front mounting hole.

– (1) Front mounting hole location (5/16 in. hole)– (2) Cab body (behind front right wheel)– (3) Panel Nuts

Heater MountingATTENTIONUse existing hardware to secure the heater if the vehicle is equipped with running boards (See Figure 1).

Connect heater harness to heater (not shown).

Install heater on cab with hardware provided.

– (1) M8 bolt, washer, panel nut (2 ea.)– (2) Heater/mounting bracket assembly

ATTENTIONPull the inner fender splash shield back to install the front mounting hardware.

Install the front mounting hardware.

– (1) Heater/mounting bracket– (2) M8 bolt, washer, and flange nut

Fig. 15

21

Fig. 16

1 2

3

Fig. 17

1

2

1

Fig. 18

1

2

12


Exhaust InstallationSecure exhaust tube to heater with 90° exhaust elbow and two clamps.

– (1) Exhaust clamp (2 ea.)– (2) Exhaust tube– (3) 90° exhaust elbow

ATTENTIONEnsure outlet end of exhaust tube is directed downward and slightly rearward 10 degrees.

Secure the exhaust tube using existing holes in body and p-clamps provided.

– (1) Exhaust tube– (2) P-clamp, M6 bolt, nut, and washer (3 ea.)

Fig. 19

1

3

2

Fig. 20

21


13

Integration into the Coolant System - 6.4 Liter TT DieselATTENTIONTorque hose clamps to 2.0 - 2.5 Nm (18 - 22 lb-in.)

Avoid sharp bends and kinks when installing coolant hoses.

Position hose clamps in such a way to avoid cutting or damaging adjacent components.

ATTENTIONClamp vehicle coolant hose with hose clamping pliers prior to cutting to prevent coolant spillage.

The coolant heater integration into the vehicle heater circuit is done in an “INLINE” fashion. Refer to Figure 21.

Coolant flow and connection detail:

Hose A: From engine to Webasto coolant pump inlet.

Hose B: From Webasto heater outlet to vehicle heater core inlet.

NOTE:Also see the plumbing schematic, page 29, of this manual for a general outline of the coolant circuit arrangement.

Fig. 21

14


Coolant Hose Connections - 6.4 Liter TT Diesel

Cut supplied hoses as shown in Figure 22.

Hose A: From engine to coolant pump inlet - Connect the 90° end to the coolant pump at the Webasto heater.

Hose B: From Webasto heater outlet to vehicle heater core inlet - Connect the 90° end to the heater outlet.

ATTENTIONInstall metal conduit on coolant hoses prior to installation.

Connect 90° end of hose “A” to Webasto heater coolant pump.

Connect 90° end of hose “B” to Webasto heater outlet.

Route coolant hoses above the inner fender splash shield to the engine compartment.

– (A) Webasto heater inlet hose– (B) Webasto heater outlet hose– (1) Hose clamp - 2ea.– (2) Coolant pump– (3) Metal conduit

ATTENTIONConfirm supply and return hoses to vehicle heater core before cutting any coolant hoses. Once confirmed, cut supply hose, leaving sufficient hose for connections.

Cut the heater core supply hose approximately 3 in. from the 90° bend in hose. Rotate supply hose toward the right side of the vehicle. See Figure 24.

Route the Webasto heater outlet hose “B” over to the heater core supply hose (90° section) and trim to proper length.

Connect the Webasto heater outlet hose “B” to the heater core supply hose with coolant adapter and two hose clamps.

Route the Webasto heater inlet hose “A” to heater core supply hose (engine side) and trim to proper length.

Connect the Webasto heater inlet hose “A” to the heater core supply hose with coolant adapter and two hose clamps.

– (1) Heater core supply hose– (A) Webasto heater inlet hose, adapter, and two

clamps– (B) Webasto heater outlet hose, adapter, and two

clamps

Fig. 22

Discard

Discard

A

B

Fig. 23

B

2

3

1

1A

Fig. 24

1

B

A


15

Integration into the Coolant System - 6.8 Liter V10 GasolineATTENTIONTorque hose clamps to 2.0 - 2.5 Nm (18 - 22 lb-in.)

Avoid sharp bends and kinks when installing coolant hoses.

Position hose clamps in such a way to avoid cutting or damaging adjacent components.

ATTENTIONClamp vehicle coolant hose with hose clamping pliers prior to removing to prevent coolant spillage.

The coolant heater integration into the vehicle heater circuit is done in an “INLINE” fashion. Refer to Figure 25.

Coolant flow and connection detail:

Hose A: From engine to Webasto coolant pump inlet.

Hose B: From Webasto heater outlet to vehicle heater core inlet.

Hose C: Connects Hose B to heater core supply hose.

NOTE:Also see the plumbing schematic, page 29, of this manual for a general outline of the coolant circuit arrangement

Fig. 25

16


Coolant Hose Connections - 6.8 Liter V10 Gasoline

Cut supplied hoses as shown in Figure 26.

Hose A: From engine to coolant pump inlet - Connect the 90° end to the coolant pump at the Webasto heater.

Hose B: From Webasto heater outlet to vehicle heater core inlet via hose C - Connect the 90° end to the heater outlet.

Hose C: From Webasto heater outlet hose to the coolant hose removed from the engine coolant outlet tube.

Prepare 180° coolant hose “C” for installation by installing coolant adapters as shown in Figure 27.

– (C) 180° coolant hose– (1) Hose clamp - 2ea.– (2) Coolant adapter - 2ea.

ATTENTIONInstall metal conduit on coolant hoses prior to installation.

Connect 90° end of hose “A” to Webasto heater coolant pump.

Connect 90° end of hose “B” to Webasto heater outlet.

Route coolant hoses above the inner fender splash shield to the engine compartment.

– (A) Webasto heater inlet hose– (B) Webasto heater outlet hose– (1) Hose clamp - 2ea.– (2) Coolant pump– (3) Metal conduit

Fig. 26

A

Discard

Discard

B C

Fig. 27

1

C

2

Fig. 28A

B

1

1

3

2


17

ATTENTIONClamp vehicle coolant hose with hose clamping pliers prior to removing hose from engine outlet.

Route Webasto heater coolant inlet hose (hose going to heater water pump) to engine outlet tube and cut to appropriate length.

Open constant tension clamp securing coolant hose to engine outlet tube and slide clamp back on hose.

– (1) Engine outlet coolant hose– (2) Constant tension clamp– (3) Engine outlet tube

Pull vehicle coolant hose off engine outlet tube and install the Webasto heater inlet hose “A” with clamp.

Route Webasto heater outlet hose “B” to the engine outlet tube and cut to the appropriate length. See Figure 30.

Install the 180° coolant hose “C” between the webasto heater outlet hose “B” and the vehicle coolant hose removed from the engine outlet tube.

– (A) Webasto heater inlet hose – (B) Webasto heater outlet hose – (C) 180° Webasto heater hose– (1) Hose clamp -2ea.– (2) Engine outlet tube– (3) Constant tension clamp– (4) Coolant hose from engine outlet tube

Install plastic protective loom over coolant hose connections as shown in Figure 31.

Secure coolant hoses with nylon cable tie.

– (1) Plastic protective loom– (2) Nylon cable tie

Fig. 29

1 2 3

Fig. 30

BA 1 2

C

3 14

Fig. 31

1 2

18


Combustion Air Intake InstallationATTENTIONObserve torque specifications.

Ensure air intake silencer is pointed downward when installed.

The combustion air intake port is located directly above the coolant pump

Install combustion air intake tube on heater.

– (1) Combustion air tube– (2) #10 Clamp. Torque 2.0 - 2.5 Nm (18 - 22 lb-in.)

Install the air silencer on the combustion air intake tube.

Route the combustion air intake tube up behind the inner fender splash shield and secure with cable ties.

Bend the combustion air intake tube so that the silencer is pointing downward.

Drill a 1/4 in hole through the splash shield near the air silencer.

Secure the air silencer to the splash shield with the clamp provided.

– (1) Air intake silencer– (2) Combustion air intake tube– (3) Inner fender splash shield

Fig. 32

1

2

Fig. 33

1 2

3


19

Integration into the Fuel System

Fuel Pump InstallationThe fuel pump is mounted horizontally along the right inside framerail using an existing hole in the frame. See Figure 34.

– (1) Fuel pump– (2) P-clamp, M6 nut and bolt– (3) Vehicle framerail (right)

ATTENTIONEnsure the fuel lines are fully seated within the fuel line couplers and any 90 degree bends are not buckled. Refer to Figure 35.

Tighten all fuel line clamps to 1.0 - 1.4 Nm (8.8 - 12.4 lb.-in.)

Fuel Line Connection at HeaterATTENTIONCover fuel line with loom to protect it form sharp edges.

Connect fuel line to heater with fuel line coupler and two clamps.

– (1) Mecanyl fuel line – (2) Fuel line coupler– (3) Fuel line clamp (2 ea.)

Fig. 34

1 2

3

Fig. 35

Fig. 36

1 2

3

20


Fuel Line and Fuel Pump Harness Routing CAUTIONSecure fuel line and fuel pump harness away from moving vehicle components and hot exhaust.

Route fuel line and fuel pump harness along right framerail towards the rear of the vehicle as shown in Figure 37.

– (1) Right framerail– (2) Mecanyl fuel line (covered with plastic loom) and

fuel pump harness– (3) Front cab mount

Route fuel line and fuel pump harness along right framerail towards the rear of the vehicle as shown in Figure 38.

– (1) Right framerail– (2) Mecanyl fuel line (covered with plastic loom) and

fuel pump harness

Fuel Line Connection at Fuel PumpATTENTIONThe outlet end of the fuel pump is quickly identified as the end with the electrical connector.

Always cut Mecanyl fuel line with a sharp razor knife or razor edged cutter. DO NOT cut with side cutters, scissors or similar tools as doing so will cause a restriction inside the fuel line.

Connect mecanyl fuel line to the outlet side of the fuel pump with fuel line coupler and two clamps.

– (1) Mecanyl fuel line– (2) Fuel line clamp (2 ea.)– (3) Fuel pump electrical connector– (4) Fuel line coupler

Fuel Pump Harness ConnectionInstall electrical connector on fuel pump harness per instructions found in electrical parts bag and connect to fuel pump.

– (1) Fuel pump harness– (2) Fuel pump harness connector– (3) Fuel pump

Fig. 37

2 31

Fig. 38

21

Fig. 39

1 2 3

4

Fig. 40

1 2 3


21

Standpipe Installation - 6.4 Liter DieselRemove fuel sending unit according to the vehicle manufacturers servicing instructions.

ATTENTIONDe-burr both sides of hole after drilling.

Drill a 8.5 mm (21/64 in.) hole through the top of the fuel sender in the location shown. See Figure 41.

– (1) Fuel sending unit– (2) 8.5 mm (21/64 in.) hole

ATTENTIONThe standpipe tube should terminate approximately 38 mm (1.5 in.) off the bottom of the fuel tank when installed.

Remove any burrs from inside cut end of tube.

Measure depth of fuel tank and cut standpipe to the appropriate length.

(1) Standpipe or fuel pickup tube

ATTENTIONEnsure standpipe does not interfere with the float arm assembly.

Install standpipe, see Figure 44 for item sequence.

– (1) Fuel sending unit– (2) Standpipe– (3) Float arm

Fig. 41

1 2

Fig. 42

1

Fig. 43

1

2

3

Fig. 44

1

2

3

4

5

6

7

Legend for Figure 441 Banjo Bolt - Torque 8.5-9.5 Nm (75-84 lb-in.)2 Banjo Fitting3 Standpipe4 Upper Sealing Washer (Black)5 Fuel Tank6 Lower Sealing Washer (Brass)7 Lock Nut - Torque 8.5-9.5 Nm (75-84 lb-in.)

22


Standpipe Installation - 6.8 Liter GasolineRemove fuel sending unit according to the vehicle manufacturers servicing instructions.

ATTENTIONDe-burr both sides of hole after drilling.

Drill a 8.5 mm (21/64 in.) hole through the top of the fuel sender in the location shown. See Figure 45.

– (1) Fuel sending unit– (2) 8.5 mm (21/64 in.) hole

ATTENTIONThe standpipe tube should terminate approximately 38 mm (1.5 in.) off the bottom of the fuel tank when installed.

Remove any burrs from inside cut end of tube.

Measure depth of fuel tank and cut standpipe to the appropriate length.

– (1) Standpipe or fuel pickup tube

ATTENTIONEnsure standpipe does not interfere with the float arm assembly.

Install standpipe, see Figure 48 for item sequence.

– (1) Standpipe or fuel pickup tube– (2) Fuel sending unit

Fig. 45

1 2

Fig. 46

1

Fig. 47

1

3

2

Fig. 48

1

2

3

4

5

6

7

Legend for Figure 481 Banjo Bolt - Torque 8.5-9.5 Nm (75-84 lb-in.)2 Banjo Fitting3 Standpipe4 Upper Sealing Washer (Black)5 Fuel Tank6 Lower Sealing Washer (Brass)7 Lock Nut - Torque 8.5-9.5 Nm (75-84 lb-in.)


23

Fuel Line Connections and RoutingInstall fuel sender assembly according to the vehicle manufacturers servicing instructions.

Connect fuel line to standpipe with fuel line coupler and two clamps. Refer to Figure 49 or 50.

Secure fuel line to existing vehicle fuel lines and install fuel tank.

(1) Fuel standpipe(2) Fuel line clamp (2 ea.)(3) Fuel line coupler(4) Mecanyl fuel line

Route Mecanyl fuel line along existing vehicle fuel lines towards crossmember. See Figure 51. Secure fuel line with nylon cable ties.

CAUTIONSecure fuel line away from moving vehicle components and hot exhaust.

Route Mecanyl fuel line to the right side of the vehicle above the vehicle crossmember shown in Figure 52. Secure fuel line with cable ties. – (1) Mecanyl fuel line exiting the crossmember at the right framerail– (2) Vehicle crossmember

1

Fig. 4924 3

6.4 Liter Diesel

Fig. 50

2 4316.8 Liter Gasoline

Fig. 51

Fig. 52

21

24


Fuel Line Connection at Fuel PumpATTENTIONAlways cut Mecanyl fuel line with a sharp razor knife or razor edged cutter. DO NOT cut with side cutters, scissors or similar tools as doing so will cause a restriction inside the fuel line.

Cut fuel line to length and connect to the fuel pump with fuel line coupler and two clamps.

(1) Fuel pump(2) Fuel line clamp (2 ea.)(3) Fuel line coupler(4) Mecanyl fuel line (covered with loom)

Power ConnectionATTENTIONThe power wire has to be extended for vehicles equipped with the 6.8 Liter V10 Gasoline engine.

Connect red power lead to battery positive terminal.

– (1) Webasto power lead– (2) Battery positive terminal

Ground ConnectionATTENTIONThe ground wire has to be extended for vehicles equipped with the 6.8 Liter V10 Gasoline engine.

Connect brown ground lead to battery negative terminal. Reconnect battery ground cable.

– (1) Battery negative terminal– (2) Webasto ground lead

Fig. 53

21 3 4

Fig. 54

21

Fig. 55

1 2


25

Final Inspection Initial Start-up and Concluding Work

Final InspectionInspect 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 chafing and related damage.– Loose fuel line clamps.– Routing of fuel lines and fuel lines securely tied and protected against chafing and related damage.– Loose wiring connections and battery connections.– routing of wiring harness and wiring harness securely tied and protected against chafing and related damage.– Check operation of vehicle heater fan with Webasto heater OFF.

Initial Start-up1 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 and coolant 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.

ATTENTIONMore than one start-up attempt of the heater may be required to purge air from fuel system before heater will start. Cycle heater Off and On after each failed start attempt until heater starts successfully. After 3 consecutive unsuccessful start attempts, the webasto control unit enters into heater lockout.See Heater Lockout section for reset instructions.

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.

ATTENTIONEngine 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.

Concluding Work – Check that all hose lines, hose clamps, pipe clips and electrical connections are secure. Secure all loose lines

and cables with nylon cable ties.– Spray the heater components and electrical connections with an anti-corrosive wax coating.– Install all vehicle parts, panels and components removed during heater installation.

26


Heater Lockout Reset Procedure

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

Reset Heater “Lockout” mode by performing the following procedure: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 after inserting fuse.

ATTENTION– The engine coolant must be below 86 °F (30 °C) before the Webasto heater will attempt to start.– Should the heater fail to start or operate correctly, contact your Webasto technical representative at:

1-800-555-4518

27


Electrical Harness Schematic - Part 1, Heater Control

28


Electrical Harness Schematic - Part 2, HVAC Blower Control

29


Heater Plumbing Schematic - Inline Method

30


NOTES:

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Mail to:Webasto Product N. A., Inc.15083 North RoadFenton, MI 48430Attention: Documentation Group

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www.webasto.uswww.techwebasto.comOrg. 02/2007 Rev. 01/2008 P/N 5001336B

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