Beruflich Dokumente
Kultur Dokumente
Coolant Heater
Installation Instructions
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 special
Webasto training, technical information, special tools 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 liability for problems and damage caused by the system being
installed by untrained personnel.
BlueHeatTM
Table of Contents
Foreword
Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . I
Tools Required. . . . . . . . . . . . . . . . . . . . . . . . . . . I
Heater Installation Site . . . . . . . . . . . . . . . . . . . . II
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
Installation
Heater Preparation and Mounting . . . . . . . . . . . . 1
Electrical Harness- - Overview . . . . . . . . . . . . . . . 2
Fuse Holder / Relays / Resistor . . . . . . . . . . . . . . . 3
Electrical Harness Routing . . . . . . . . . . . . . . . . . . 3
Integration with HVAC Blower Motor . . . . . . . . . 4
Timer Installation - Model 1533 . . . . . . . . . . . . . 5
Ignition On Fuse Tap Connection. . . . . . . . . . . . 5
Integration into the Fuel System . . . . . . . . . . . . . 6
Foreword
Scope and Purpose
These non-binding installation instructions are intended to support authorized Webasto trained distributors,
dealers and personnel in the installation of the Thermo Top BlueHeat coolant heaters.
These non-binding installation instructions apply to the 2004 Lexus RX330, 3.3 liter gasoline version, unless
technical modifications 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 must be followed. Acknowledged engineering conventions must be observed for the installation work.
ATTENTION
All relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary
heating devices must be observed!
CAUTION
Location 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.
Tools Required
1/4 Drive Ratchet
1/4 Drive 4 inch extension
10 mm six point socket, 1/4 drive
10 mm six point deep well socket, 1/4 drive
Drill
2.5 mm (3/32 in.) drill bit
8.5 mm (21/64 in.) drill bit
9.5 mm (3/8 in.) drill bit
10 mm (25/64 in.) drill bit
10 mm combination wrench
8 mm nut driver
Hacksaw
Utility Knife
Wire fish
Hoisting equipment and safety stands
Vehicle manufacturers service reference manual
Phillips #2 screwdriver
BlueHeatTM
Mounting Location
Fig. 1
Mounting Location
Heater Installed
Fig. 2
Preparations
Heater Kit
1. Verify and identify all contents of kit.
Vehicle
1. Verify fuel content in tank.
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 3/4 tank or less of fuel present.
If fuel quantity is greater than 3/4 of capacity, make provisions to reduce quantity of fuel.
2. Disconnect negative terminal of vehicle battery(s).
3. Remove front facia.
4. Protect vehicle against soiling and damage with fender covers and seat covers.
II
Position 1 and 2:
Fasten bracket to heater using 2 M6 self-tapping EJOT
screws.
Torque screws to 10 Nm. (88.5 lb-in.).
Fig. 3
Position 3 and 4:
Relocate ground splice to location shown.
4
Fig. 4
Heater
Bracket
Position 5, 8 and 9
Install outboard mounting bracket on heater with 2
M6 self-tapping EJOT screws
Torque screws to 10 Nm. (88.5 lb-in.).
Position 6, 7 and 8
Install outboard mounting bracket on vehicle body
with existing and new hardware.
Fig. 5
Position 10 and 11
Install outboard mounting bracket on vehicle body
with existing and new hardware.
10
Fig. 6
11
2
1
3
26
25
24
22
21
23
7
20
19
8
9
10 11
18
16
12
13
Fig.
Fig. 77
15
14
ATTENTION
The electrical harness is a two-part assembly. Before
installing, cut wire tie holding the negative side HVAC
blower harness (with relay K3) to the main harness and
separate.
Fuse Holder Position 1
Relays and
Assemble mounting brackets as shown.
Resistor
Assembly
Position 2 and 3
Fasten K1 and K2 relays to bracket.
Install resistor on bracket.
3
Fig. 8
2
4
Position 4 and 5
Fasten relay/resistor bracket assembly to body with two
screws.
Fasten fuse holder to bracket assembly or vehicle
structure using nylon wire tie (Image not available).
5
Fig. 9
Position 6 and 7
Route main harness down to heater mounting location
and connect to heater.
Secure main harness with nylon wire ties.
Fig. 10
Position 8, 9 and 10
Route timer and blower control harness through
vehicle bulkhead.
9
10
Fig. 11
3
ATTENTION
It is permissible to cut excess length from blower control
wiring harnesses.
HVAC
Blower
Control
Harness
Integration
Position 1 and 2
Locate vehicle blower motor under passenger side of
vehicle dash.
Locate blower motor harness connector, cut blower
motor positive and negative wires approximately 2
inches from connector.
Mount K3 relay under dash (Image not available).
Fig. 12
Make HVAC Blower wiring connections as follows:
Position 3
Cut, strip and crimp
Position 4
Cut, strip and crimp
Position 5
Cut, strip and crimp
Position 6
Cut, strip and crimp
Position 7
Connect to chassis ground
Position 8
Crimp green wire to green wire
ATTENTION
Check your wiring! Ensure that all connections have
been done in accordance with the accompanying wiring
diagram (Fig. 13). Sensitive electronic controls can be
damaged if wired incorrectly!
8
7
Fig. 13
Additional
Secure HVAC blower control wiring to vehicle
structures with nylon wire ties (Image not available)
Timer
Installation
Fig. 14
Fig.
ATTENTION
DO NOT OVERTIGHTEN MOUNTING SCREW!
Overtightening mounting screw will cause stress on the
timer resulting in irreparable damage to the LED display.
Position 9
Timer installed (See translated template for
instructions, refer to figure 14).
Screw DIN7981 B3.5x19
Timer harness connector (Click in)
Tighten mounting screw - max. 0.8 Nm (7.0 lb-in.).
Fig. 15
Fig.
Fig.
Ignition On
Position 10 and 11
Fuse Tap
Route the blue fuse tap wire to fuse panel.
Installation
With a test light, find an Ignition ON power source.
Test light must be off when ignition key is in the OFF
position.
Using the supplied fuse tap connector, tap into the
fusedside of the selected fuse.
Fig. 16
5
11
10
Position 1
Remove drivers side fuel sender.
WARNING
Fire and explosion risk! Do not use an electric power
drill to bore into the sender unit as vaporizing fuel can
be ignited. Keep all sources of ignition away from the
fuel tank and work area.
Fig. 17
2
Position 2
Bore an 8 mm (5/16 in.) hole.
1
Fig.11
18
Fig.
Position 3
Standpipe (bend tube as necessary to clear moving
parts and cut to length).
203.2 mm (8in.)
Fig. 19
6
4
5
6
7
Position 4 and 7
Install fuel standpipe with outlet aligned as shown.
Tighten lock-nut to 9.0 - 9.5 Nm (80 - 84 lb-in.)
Return fuel sender to fuel tank.
Position 9, 10 and 11
Pre-assemble rubber fuel line adapter with two hose
clamps.
Install adapter on standpipe and secure inboard clamp.
Insert fuel line fully into adapter and secure outboard
clamp.
Tighten hose clamps to 1.0-1.4 Nm (8.8-12.4 lb-in.)
Cover fuel line with loom.
Fig. 20
8
4
10
11
Fig. 21
ATTENTION
Observe Figure 22 for correct fuel line connecting.
Fig. 22
Fuel Pump
Installation
Position 12 and 13
Mount Fuel pump to vehicle using existing stud and
P- clamp provided.
Fig. 23
7
13
12
Fig. 24
5
4
6
Position 5, 6, 7, and 8
Connect remaining section fuel line to fuel pump
outlet with rubber adapter and two hose clamps.
Tighten clamps to 1.0-1.4 Nm (8.8-12.4 lb-in.)
Position 9 and 10
Route fuel pump harness to fuel pump following
vehicle fuel lines.
Assemble fuel pump harness connector (assembly
instructions provided in kit) and connect to fuel pump.
FRONT
Fig. 25
Fuel Line
and Cable
Routing
11
FRONT
Fig. 26
14
13
12
15
18
Fig. 27
8
10
16
17
NOTE:
Torque all hose clamps to 1.5 - 2.0 Nm (13 - 18 lb-in.).
Preparing
Heater
Hoses For
Connection
Position 1, 2 and 3
Cut coolant supply hose to heat exchanger between
hose clamping pliers.
Fig. 28
Position 4, 5 and 6
Install 90 degree coolant hose on heater outlet with
clamp.
4
5
6
Fig. 29
7
Position 7, 8 and 9
Install 180 degree coolant hose on heater inlet with
clamp.
Fig. 30
Position 9, 10, 11 and 12
Route heater inlet and outlet hoses between air box
bracket and engine.
Cover hoses with loom where they come into contact
with air box bracket.
Reposition coolant supply hose coming from engine as
shown.
Connect heater inlet hose to coolant supply hose with
adapter and to hose clamps.
Position 13, 14, 15 and 4
Connect heater outlet hose to hose going to heat
exchanger with adapter and two clamps.
9
Fig. 31
10 11 12
15 14
13
Position 1and 2
Install 90 degree exhaust elbow on heater.
Tighten clamp to 5 - 5.5 Nm (44 - 49 lb-in.)
Fig. 32
Position 3 and 4
Remove 216mm (8.5 in.) from exhaust tube.
Cover exhaust tube with high temp wrap.
Install exhaust tube on 90 degree elbow.
Tighten clamp to 5 - 5.5 Nm (44 - 49 lb-in.)
3
4
Fig. 33
Position 4, 5 and 6
Secure exhaust tube to oil cooler bracket with P-clamp
and new longer bolt.
4
Fig. 34
Position 4, 7 and 8
Drill hole through lower splash shield and install high
temp doughnut.
Route exhaust tube through hole in splash shield.
7
4
Fig. 35
10
Position 1 and 2
Install split end of combustion air intake tube on heater
with narrow band hose clamp.
Fig. 36
Position 1 and 3
1
ATTENTION
The silencer must be pointed in a downward direction!
Route combustion air intake tube in front of battery.
Thread silencer into the end of the combustion air tube
Secure combustion air intake tube to coolant lines with
nylon wire ties.
Fig. 37
11
Initial Startup
Final Inspection
1. Check all fasteners to ensure system is secure.
2. Check routing of coolant lines and ensure coolant lines are securely tied and protected against chaffing and
related damage.
3. Check routing of air intake and exhaust lines and ensure lines are secure. Keep hot exhaust components away
from heat sensitive vehicle components and fuel lines.
4. Check routing of fuel lines and ensure fuel lines are securely tied and protected against chaffing and related
damage.
5. Check routing of wiring harnesses and ensure wiring harnesses are securely tied and protected against chaffing
and related damage.
6. Check for loose wiring connections and battery connections.
7. Check operation of vehicle heater fan with Webasto heater OFF.
Initial Start-up
1. 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.
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. If heater should fault
to the lock-out mode, which is possible after three start attempts, refer to Troubleshooting and follow directions
under Heater Lockout Reset Procedure. No further start attempts are possible until the lockout condition is
cleared.
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.
7. Install all vehicle components removed during heater installation.
8. Place Owners Manual and related documentation in vehicle.
12
13
Basic Troubleshooting
Basic Troubleshooting
General Information
This section describes troubleshooting procedures for the BlueHeat coolant heater within the scope of installation.
Troubleshooting is normally limited to the isolation of defective components and provides information on defective
wiring and connections.
Should the heater not function after completing the installation and initial start-up instructions, refer to the
following troubleshooting instructions and information to isolate and remedy the cause for malfunction.
In the event you are unable to remedy a malfunction after following these troubleshooting instructions or for
unanticipated malfunctions beyond what is covered in this troubleshooting section, please contact one of our
Webasto Technical Assistance Representatives for further instructions.
In the USA, call (800) 555-4518
In Canada, call (800) 667-8900
CAUTION
Advanced troubleshooting requires comprehensive knowledge about structure and theory of operation.
Advanced troubleshooting of the heater and components may only be performed by Webasto trained and
certified, professionals.
Before troubleshooting, check for and eliminate the following probable causes for trouble:
power supply to heater is less than 10.5 volts at main power connections. Charge batteries and perform load
test to ensure proper battery performance.
blown fuses.
corrosion on battery terminals for heater, electrical wiring, connections and fuses.
loose contacts or connectors, wrong crimping on connectors.
ensure heater and components have been correctly installed following all pertaining installation instructions.
shut down initiated by temperature limiter.
heater control unit locked out. Refer to heater lockout reset procedure.
ATTENTION
After correction of a malfunction, a functional test has to be performed with heater installed on the vehicle.
14
Basic Troubleshooting
Malfunction Symptom
Coolant heater switches
off automatically (Fault
lockout)
Probable Cause
Remedy
Heater overheats
Charge battery
Switch off heater momentarily and switch on once
again
15
Schematics
16
Schematics
17
Schematics
Plumbing Schematic
18
Org. 07/2003
P/N 5000684A
www.webasto.us
www.techwebasto.com