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Webasto blueheat airtop 2000 Installation Manual

Summary of blueheat airtop 2000

  • Page 1

    Blueheat airtop 2000 heater airtop 2000 heater installation manual required tools table of contents dodge sprinter (passenger van) 2003 2.7 liter diesel special instructions for these models part locations may differ slightly dependent on the vehicle model. Doc p/n 5000712a kit p/n 5000389b printed ...

  • Page 2

    – 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 tool...

  • Page 3

    3 dodge sprinter passenger van blueheat tm parts list vehicle information foreword this installation requires special expertise from a webasto training course to install a webasto air top 2000, which means that it may only be installed by a specially trained workshop or dealership. Webasto cannot ac...

  • Page 4

    4 blueheat tm dodge sprinter passenger van symbol identification symbols 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 ...

  • Page 5

    Dodge sprinter passenger van blueheat tm 5 general references – bare body parts, for example around drilled holes, must be treated with anti-corrosive coating. – secure hoses, cables and wiring harnesses with cable ties and fit protective hoses around them at chafing points. – fit edge protectors (o...

  • Page 6

    6 dodge sprinter passenger van heater cut out location timer control location vehicle fuse panel webasto heater fuel pump installation component location - overview attention position webasto timer control into vehicles auxiliary switch panel located on the center console next to the 12v power socke...

  • 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. Blueheat tm.

  • 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 compo...

  • Page 9

    Dodge sprinter passenger van 9 mounting the air top 2000 heater – (1) air top 2000 mounting location attention using far right seat mounting bracket as a guide, position the right front corner of template 12 1/2 inches from rear of seat bracket. Maintain a 2 inch gap between seat bracket and templat...

  • Page 10

    10 dodge sprinter passenger van attention temporarily place the heater in position and place 4 locator bolts through the mounting plate. Cut the carpet using the heater mounting plate as a template. Remove the heater and carpet remnant. – (1) air top 2000 heater – (2) mounting bracket attention prev...

  • Page 11

    Dodge sprinter passenger van 11 installing the electrical harness attention remove top access cover from heater and plug the harness into the control unit receptacle socket as shown. Attention pull back rear mat to access plywood from heater mounting location to back on front seats. Cut a 1 inch wid...

  • Page 12

    12 dodge sprinter passenger van attention from the lower right side of the center console, butt splice the red and black wires added to the timer harness loom into the power connection harness. Connect the red wire to the red 12 gauge power wire and the black wire to the brown 12 gauge ground wire. ...

  • Page 13

    Dodge sprinter passenger van 13 attention route red power wire through access channel that runs under floor mat to the drivers seat. – (1) access channel to drivers seat – (2) red power wire to fuse panel attention locate fuse panel and butt splice positive wire to the fused side of fuse 15. (25 amp...

  • Page 14

    14 dodge sprinter passenger van integration into fuel system caution fig. 17shows correct fuel line connections versus incorrect connection. Please observe. Caution fuel pump must be mounted horizontally to function correctly. Attention prior to fuel pump installation, push rubber fuel line connecto...

  • Page 15

    Dodge sprinter passenger van 15 caution when cutting fuel line to length, always use a sharp razor knife or blade. Never cut fuel line with side cutters or similar tools as they will crimp the line closed. Attention cut the oem fuel pump outlet line above fuel tank. Refer to fig. 21. Pay special att...

  • Page 16

    16 dodge sprinter passenger van attention install protective loom over heater fuel line and connect 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) ...

  • Page 17

    Dodge sprinter passenger van 17 combustion air intake 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 fi...

  • Page 18

    18 dodge sprinter passenger van exhaust routing and installation attention route exhaust tube from 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 prop...

  • Page 19

    19 dodge sprinter passenger van timer wiring diagram blueheat 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...

  • Page 20

    20 dodge sprinter passenger van wiring schematic blueheat tm.

  • Page 21

    21 dodge sprinter passenger van concluding work 1. Install all vehicle parts, panels and components removed during heater installation. 2. Secure all loose lines and cables with nylon cable ties. 3. Spray the heater components and electrical connections with an anti-corrosive wax coating. Final insp...

  • Page 22

    Dodge sprinter passenger van 22 heater maintenance the webasto blueheat heater is designed for minimal maintenance. Under normal circumstances it should be inspected for proper function at least once annually, preferably, just prior to the heating season. To ensure trouble-free operation, the follow...

  • 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.