8.7
Removal and Installation
CAUTION
In installed condition only the following removal and dis-
assembly procedures are allowed, the upper housing
shell being accessible for removal:
l
Replacement of control unit
l
Replacement of temperature limiter
8.7.1 Air Heater, Removal and Installation
8.7.1.1 Removal
1. Disconnect
battery
terminal
leads.
2.
Withdraw cover from upper housing shell according
to 9.2.1.1.
3.
Disconnect plug of cable loom from control unit.
4. Disconnect
cable
to
dosing
pump
at
cable
disconnect.
5. Disconnect fuel inlet on air heater.
6.
Disconnect connections of combustion air intake and
exhaust outlet on air heater.
7.
Remove four nuts and lock washers on air heater.
8.
Remove air heater and discard gasket.
8.7.1.2 Installation
1. Locate air heater with new gasket in installation
position and secure with four nuts and lock washers
(use original Webasto nuts only).
2. Tighten nuts with 6 + 1 Nm.
3. Secure connection for fuel inlet on air heater.
4. Secure connections for combustion air inlet and ex-
haust outlet on air heater.
5. Route cable to dosing pump and connect to dosing
pump.
6. Connect plug of cable loom to control unit.
7. Plug on cover and arrest.
8. Reconnect battery terminal leads.
9. Bleed fuel supply system.
8.7.2 Replacement of Control Unit
8.7.2.1 Removal
NOTE
During removal avoid the build-up of static charge (i.e.
do not touch strip conductors).
1. Withdraw cover from upper housing shell according
to 9.2.1.1.
2. Disconnect plug of cable loom from control unit.
3.
Withdraw covers for heating air inlet and outlet
(5 and 3) according to 9.2.1.2.
4.
Remove upper shell according to 9.2.3.1.
5. Disconnect plugged connections (1, Fig. 815 or Fig.
816) of terminal.
6. Remove screws (3) and remove control unit (2).
8.7.2.2 Installation
CAUTION
When installing a new control unit in heaters Air Top
2000 without diagnosis, it is mandatory to observe the
remarks in 8.8.
NOTE
During installation avoid the build-up of static charge (i.e.
do not touch strip conductors).
1. Locate control unit (2, Fig. 815) in installation position
and secure with screws (3). Ensure control unit en-
gages in arrester groove (6). Torque screws to
0.5 Nm.
2.
Connect plug connections to terminal (Fig. 701 or
Fig. 702).
3. Plug on upper housing shell and fix in position.
4. Slide on covers for heating air inlet and outlet and fix
in position.
5.
Connect plug of cable loom to control unit.
6.
Fit cover and fix in position.
8.7.3 Replacement of Temperature Limiter
8.7.3.1 Removal
1. Withdraw cover from upper housing shell according
to 9.2.1.1.
2. Disconnect plug of cable loom from control unit.
3. Withdraw covers for heating air inlet and outlet accord-
ing to 9.2.1.2.
4. Remove upper housing shell according to 9.2.1.3.
5.
Disconnect plugged connection (blue) from terminal.
6. Remove lock washers (4, Fig. 815 or Fig. 816).
7.
Remove temperature limiter (5).
8.7.3.2 Installation
1.
Locate temperature limiter (5, Fig. 815 or Fig. 816) in
installation position and secure with lock washers
(4). Ensure that temperature limiter rests properly
on heat exchanger.
2.
Connect plug connections (blue) to terminal.
3.
Plug on upper housing shell and fix in position.
4.
Slide on covers for heating air inlet and outlet and fix
in position.
5.
Connect plug of cable loom to control unit.
6. Fit cover and fix in position.
808
8 Servicing
Air Top 2000