804
Thermo G
8 Repair
8.6
Control device removal and
Installation
Removal
1. Disconnect the heater from the vehicle electrical
system. Disconnect the plug “C“.
2. Disconnect the circulating pump plug “P“.
3. Disconnect the gas pressure regulator plug “V“.
4. Disconnect the temperature sensor plug “T“ (5, Fig.
802).
5. Remove hood (see 8.3).
6. Disconnect the plug of the ZF module (8, Fig. 804) and
the fan motor (2) plug from the control device (5).
7. Remove the control device attaching screw (5).
8. Remove the control device (5).
Installation
1. Position control device (5, Fig. 804) to fan housing (3).
2. Screw in the attaching screw of the control device and
tighten it (2 +0.5 Nm).
3. Plug the ZF module plug (8) and the fan motor plug (2)
into the control device (5).
4. Install hood (see 8.3).
5. Plug in the temperature sensor plug „T“ (5, Fig. 802).
6. Plug in the gas pressure regulator plug „V“.
7. Plug in the circulating pump plug „P“.
8. Plug in „C“ plug.
8.7
Fan wheel removal and installation
Removal
1. Separate the fan housing from the mixing chamber
(see 8.5).
ATTENTION:
Do not overstretch the circlip.
2. Remove the fan wheel (4, Fig. 804). For that first
remove the shaft circlip (7) using suitable pliers. Then
remove the fan wheel.
Installation
1. Remove any residuals of the mixing chamber seal (9,
Fig. 804) from fan housing and/or from the mixing
chamber.
2. Slide fan wheel (4) onto the motor shaft. Install shaft
circlip (7) with suitable pliers.
ATTENTION:
Do not use an overstretched shaft circlip! Ensure
secure engagement of the circlip in the groove!
Verify the fan wheel is freely rotatable.
3. Attach fan housing to the mixing chamber (see 8.5).
8.8
Fan motor removal and installation
Removal
1. Separate the fan housing from mixing chamber (see
8.5).
ATTENTION:
Do not overstretch the circlip.
2. Remove the fan wheel (4, Fig. 804). For that first
remove the shaft circlip (7) using suitable pliers. Then
remove the fan wheel.
3. Remove 3 countersunk screws securing the fan motor
(2) to the fan housing (3) and remove the fan motor
from fan housing (2).
Installation
1. Position fan motor (2, Fig. 804) onto the fan housing
(3) and secure the fan motor (2) using 3 countersunk
screws M5x35 (5 +1 Nm).
2. Slide fan wheel (4) onto the motor shaft. Install shaft
circlip (7) with suitable pliers.
ATTENTION:
Do not use an overstretched shaft circlip! Ensure
secure engagement of the circlip in the groove!
Verify the fan wheel is freely rotatable.
3. Attach fan housing to the mixing chamber (see 8.5).
8.9
ZF module removal and installation
Removal
1. Separate the fan housing from the mixing chamber
(see 8.5).
2. Remove screw and serrated lock washer, securing
the ground cable of the ZF module (8, Fig. 804) to the
mixing chamber.
3. Remove screws, securing the ZF module to the
mixing chamber and remove the ZF module along
with the gasket and the ignition electrodes from the
mixing chamber.
Installation
1. Position ZF module (8, Fig. 804) along with the
ignition electrodes and gasket into the mixing
chamber.
2. Secure ZF module to the mixing chamber using 2
screws.
3. Attach ground cable of the ZF module to the mixing
chamber with a screw and a serrated lock washer.
4. Attach fan housing to the mixing chamber (see 8.5).
