Webasto BlueHeat Thermo Top Manual Download

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DOC P/N 5001336B

KIT P/N 5001335C

Printed in USA

Webasto Product N.A., Inc.

Blue

Heat

Coolant Heater

Thermo Top

Special Tools

– Hose Clamping pliers
– Torque Wrench

Table of Contents

Ford F-250/350 Super Duty

6.4 Liter TT Diesel
6.8 Liter V10 Gasoline
Beginning Model Year: 2008

Special instructions for these models

Part locations may differ slightly dependent on
the vehicle model.

Foreword

Parts List

Vehicle Information

Scope and Purpose

Symbol Identification

General References

Preparation 5
Heater Installation Site

Installation

Electrical - Overview

Electrical Harness Installation

Timer Installation

Fuse Tap Connection - Relay K-1

Integration into the Blower System

3-Relay HVAC Harness Connections

K3 Relay Ground

Heater Control and Fuel Pump Harness Routing

Heater Preparation and Installation

Heater Mounting

Exhaust Installation

Integration into the Coolant System -
6.4 Liter TT Diesel

Coolant Hose Connections -
6.4 Liter TT Diesel

Integration into the Coolant System -
6.8 Liter V10 Gasoline

Coolant Hose Connections -
6.8 Liter V10 Gasoline

Combustion Air Intake Installation

Integration into the Fuel System

Fuel Pump Installation

Fuel Line and Fuel Pump Harness Routing

Standpipe Installation - 6.4 Liter TT Diesel

Standpipe Installation - 6.8 Liter V10 Gasoline

Power Connection

Ground Connection

Final Inspection, Initial Start-up and Concluding
Work

Heater Lockout Reset Procedure

Electrical Harness Schematic - Part 1

Electrical Harness Schematic - Part 2

Heater Plumbing Schematic - Inline Method

Summary of Contents for BlueHeat Thermo Top

Page 1: ...ay HVAC Harness Connections 9 K3 Relay Ground 10 Heater Control and Fuel Pump Harness Routing 10 Heater Preparation and Installation 11 Heater Mounting 11 Exhaust Installation 12 Integration into the Coolant System 6 4 Liter TT Diesel 13 Coolant Hose Connections 6 4 Liter TT Diesel 14 Integration into the Coolant System 6 8 Liter V10 Gasoline 15 Coolant Hose Connections 6 8 Liter V10 Gasoline 16 C...

Page 2: ...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 I...

Page 3: ...icial Marks of Conformity Scope and Purpose These 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 he...

Page 4: ...mbols 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: ...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 instructio...

Page 6: ... to the vehicle s own wires and cable harnesses ATTENTION Timer 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 2 1 1 2 1 ...

Page 7: ...orner 2 Electrical mounting bracket assembly CAUTION Use 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 Installation CAUTION Check behind panels for obstructions before drilling holes AT...

Page 8: ...elay center 2 Fuse tap ATTENTION The 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 System Route Blower harness over to blower area Mount negative side blower harness and relay in vicinity of HVAC blower Wire according to schematic in...

Page 9: ...iring 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 Motor K3 Relay Negative Side of ...

Page 10: ...ses 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 contr...

Page 11: ...unning 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 Mounting ATTENTION Use 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...

Page 12: ...wo clamps 1 Exhaust clamp 2 ea 2 Exhaust tube 3 90 exhaust elbow ATTENTION Ensure 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 2 1 ...

Page 13: ...ATTENTION Clamp 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 schemat...

Page 14: ...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 lengt...

Page 15: ...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 Al...

Page 16: ... 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 ATTENTION Install 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 ...

Page 17: ...stall 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 Eng...

Page 18: ... 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...

Page 19: ...rail right ATTENTION Ensure 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 Heater ATTENTION Cover 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 li...

Page 20: ...ss Fuel Line Connection at Fuel Pump ATTENTION The 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 fu...

Page 21: ... 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 ATTENTION Ensure 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 ...

Page 22: ...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 ATTENTION Ensure 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...

Page 23: ...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 CAUTION Secure 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 ...

Page 24: ...amp 2 ea 3 Fuel line coupler 4 Mecanyl fuel line covered with loom Power Connection ATTENTION The 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 Connection ATTENTION The ground wire has to be extended for vehicles equipped with the 6 8 Liter V10 Ga...

Page 25: ...se connections for leaks Coolant level in expansion tank Add coolant as needed 4 Switch off the engine ATTENTION More 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 in...

Page 26: ...out 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 ...

Page 27: ...27 Ford F 250 350 Super Duty Truck BlueHeatTM Electrical Harness Schematic Part 1 Heater Control ...

Page 28: ...28 BlueHeatTM Ford F 250 350 Super Duty Truck Electrical Harness Schematic Part 2 HVAC Blower Control ...

Page 29: ...29 Ford F 250 350 Super Duty Truck BlueHeatTM Heater Plumbing Schematic Inline Method ...

Page 30: ...30 BlueHeatTM Ford F 250 350 Super Duty Truck NOTES ...

Page 31: ...ntation Thank you Unsatisfactory Excellent Please rate the overall usefulness of the documentation 1 2 3 4 5 Rate the completeness and clarity of the instructions did the procedures provide enough detail 1 2 3 4 5 What could be added or clarified Please list any other comments concerns or suggestions Please provided contact information below Name Company Name City State Phone Email Mail to Webasto...

Page 32: ...Webasto Product N A Inc Technical Assistance Hotline USA 800 555 4518 Canada 800 667 8900 www webasto us www techwebasto com Org 02 2007 Rev 01 2008 P N 5001336B ...

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