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Webasto blueheat airtop 2000, Installation Manual, Page: 8 / 24

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Webasto blueheat airtop 2000 Installation Manual Download Page 8

8

Dodge Sprinter Passenger Van

Universal Mounting Plate

A mounting template has been included with the heater kit for ease of installation.

The template details all required hole locations and clearances. Also, check for clearance around sub-floor cross-mem-
bers, structures and heat sensitive components before proceeding with installation.

TEMPLATE NOT TO SCALE

100 mm (4 in.) Hole

8 mm (5/16 in.) Drill Bit

NOTE:
ALLOW 155mm (6 in.) CLEARANCE FOR DUCTING

Blue

Heat

TM

Summary of Contents for blueheat airtop 2000

Page 1: ...t driver Phillips 2 screwdriver Combination side cut crimping pliers Drill 2 5 mm 3 32 in drill bit 8 mm 5 16 in drill bit 10 mm 25 64 in drill bit Hacksaw Utility Knife Mechanic s wire 2 feet Hoisting equipment and safety stands Vehicle manufacturer s service reference manual Foreword Parts List 3 Vehicle Information 3 Scope and Purpose 3 Symbol Identification 4 General References 5 Preparation 5...

Page 2: ...ols 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 ...

Page 3: ...difications 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 Air Top 2000 must be followed Acknowledged engineering conventions must be observed f...

Page 4: ...ols 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 ...

Page 5: ...er Kit Verify and identify all contents of kit 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 or less of fuel present If fuel quantity is greater than 1 4 of capacity make provisions to reduce quantity of fuel Heater Installation Site ATTENTION The Webasto Air Top 2000 Heater is to b...

Page 6: ...lation Component Location Overview ATTENTION Position Webasto Timer Control into vehicles auxiliary switch panel located on the center console next to the 12v power socket 2 Location Center Console 1 Location Under first row of rear seats 3 Location Under Drivers Seat 4 Location Over Driveshaft Near Fuel Tank 1 2 3 4 BlueHeatTM ...

Page 7: ...7 Dodge Sprinter Passenger Van Component Break down Typical Some components may be different or not included in the vehicle specific Dodge Sprinter Passenger Van heater kit as shown BlueHeatTM ...

Page 8: ...installation The template details all required hole locations and clearances Also check for clearance around sub floor cross mem bers structures and heat sensitive components before proceeding with installation TEMPLATE NOT TO SCALE 100 mm 4 in Hole 8 mm 5 16 in Drill Bit NOTE ALLOW 155mm 6 in CLEARANCE FOR DUCTING BlueHeatTM ...

Page 9: ...2 Seat Mounting Bracket CAUTION Always check for obstructions under vehicle before drilling Remove obstructions if necessary Drill 4 outside mounting holes center and towards rear of the template using a 8 mm 5 16 in drill bit The two holes closest to the front seats require self tapping sheet metal screws ATTENTION Using a hole saw or similar large hole cutter cut a 100 mm 4 in hole in the center...

Page 10: ...e heater and carpet remnant 1 Air Top 2000 Heater 2 Mounting Bracket ATTENTION Previous to mounting the heater secure both the exhaust tube and Intake tube to heater Connect a 90 degree fuel line elbow that points towards the left side of the vehicle if the heater were installed Do NOT mount heater at this time 1 Combustion Air Intake Tube 2 90 Degree fuel Line Adapter 3 Exhaust Tube Fig 5 1 2 Fig...

Page 11: ...or mat to right side of center console 1 Floor Mat Retainer Plate 2 Location of Channel to be Removed ATTENTION Fish timer harness from right lower center console area up to timer mounting location Cut wire to length and remove harness from center console Remove the red and black wires from the cut off section of the harness Add these two wires to timer harness loom and re fish harness back up to ...

Page 12: ...Wire From Power Harness Timer Installation ATTENTION Wire timer harness connector in accordance to the wiring diagram located on page 19 Install timer Model 1531 in the auxiliary switch panel located on the center console next to the 12v power socket 1 Timer Control Power Harness Connection ATTENTION Route power harness across passenger foot well area over along side passenger seat Use the access ...

Page 13: ...with the wiring diagrams located in the back of this book Sensitive electronic controls can be damaged if wired incorrectly CAUTION Torque all mounting bolts evenly Do not over tighten mounting fasteners Mounting plate distortion may occur resulting in fan motor failure Ensure the heater base and gasket covers the entire hole ATTENTION Mount heater to bracket using provided hardware Mount Heater B...

Page 14: ...amper Install damper on fuel pump located on rear side of vehicle crossmember and above driveshaft Tighten clamps leaving the outboard clamp loose for fuel line connection 1 Fuel Pump P Clamp 2 Heater Fuel Pump 2 Vehicle Driveshaft ATTENTION Route fuel pump harness from heater through rear crossmember access hole Secure to left rear heater mounting stud 1 Fuel Pump Harness ATTENTION Wrap excess fu...

Page 15: ...mps ATTENTION Depending on kit model and application a fuel filter may be supplied If the heater kit does not include a fuel filter you can purchase an optional filter from Webasto Order genuine Webasto fuel filter P N 487171 The filter can be installed anywhere between the fuel tap connection and the fuel pump inlet Typically the filter is installed at the fuel pump inlet ATTENTION Install protec...

Page 16: ...line to fuel pump outlet Route fuel line as shown through crossmember access hole and connect to the previously installed 90 degree elbow at heater Ensure all fuel clamps have been tightened 1 Fuel line to Heater 1 Fuel Line to Heater from other side of cross member Fig 24 1 Fig 25 Heater Fuel Pump 1 ...

Page 17: ...ake ATTENTION Route combustion air Intake tube from heater towards front of vehicle pointing tube end downward Secure with supplied P Clamps 1 Combustion Air Intake Tube 1 Combustion Air Intake Tube Installed 2 Exhaust Tube Installed Fig 26 1 Fig 27 1 ...

Page 18: ... heater towards rear of vehicle Secure with supplied P Clamps 1 Exhaust Tube ATTENTION Ensure end of exhaust tube is pointing downwards ATTENTION If heat insulators are used ensure they are properly positioned and that the tail pipe is positioned downward 1 Exhaust Tube 2 P Clamp Fig 28 1 Fig 29 1 2 ...

Page 19: ...eHeat with timer 88206A 7 Day Digital Timer Model 1531 with Temperature Rheostat Battery Negative 4 12 Blue 6 Red 8 White 9 Battery Negative 4 ground Dash Lights 1 optional Battery Positive 10 Battery Negative 12 ground Battery Positive 11 Black 2 BlueHeatTM ...

Page 20: ...20 Dodge Sprinter Passenger Van Wiring Schematic BlueHeatTM ...

Page 21: ...ions Routing of wiring harness and wiring harness securely tied and protected against chafing and related damage Initial Start up 1 Set time and day of week on heater timer according to operating instructions found in the owners manual 2 Switch on the Webasto heater by means of the instant heat button on timer and check Timer panel and instant heat indicator illuminates Initiation of start up sequ...

Page 22: ...te the heater a minimum of 10 minutes every month to keep fresh fuel in the system and the fuel pump lubricated 2 Keep the heating air outlet clear of obstructions 3 Keep the heater inlet grille clear of obstructions 4 Inspect the combustion air tube and exhaust tube for obstructions and damage Check to ensure they are securely attached to the heater and vehicle Repair damaged items where necessar...

Page 23: ...23 NOTES ...

Page 24: ...Webasto Product N A Inc Technical Assistance Hotline USA 800 555 4518 Canada 800 667 8900 www webasto us Org 10 2003 Rev N A P N 5000712A ...

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