- DL manuals
- Webasto
- Heater
- BlueHeat
- Installation instructions manual
Webasto BlueHeat Installation instructions manual
Summary of BlueHeat
Page 1
Dodge ram 2500 / 3500 2003 / 2004 - 5.7 liter gasoline 2003 / 200 6 - 5.9 liter diesel 2007 6.7 liter diesel installation instructions blueheat coolant heater doc p/n 5000681b kit p/n 5000498 c.
Page 2: - D
1 p reliminary i nformation b lue h eat - d odge r am 2500 / 3500 2 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-...
Page 3: - D
Vehicle preparations heater kit 1. Verify and identify all contents of kit. Vehicle 1. Verify fuel content in tank. 2. Disconnect negative terminal of vehicle battery(s). 3. Remove lower instrument panel fascia (above steering column) to gain access to timer and blower motor harness. Refer to vehicl...
Page 4: - D
2 i nstallation b lue h eat - d odge r am 2500 / 3500 4 universal electrical harness - description legend for figure 3 1- fuse holder and fuses 2- resistor - hvac blower speed control 3- relay k1 - hvac control 4- relay k2 - hvac control 5- 18 ga green - ‘on’ signal from relay k1 and k2 to relay k3,...
Page 5: - D
B lue h eat - d odge r am 2500 / 3500 2 i nstallation 5 1 fig. 4 installation – drill two holes in vehicle bulkhead (1) for mounting the fuse, relay, resistor cluster. Refer to figure 4. – install two relays (3) and resistor (2) on mounting bracket (4) with hardware provided. Refer to figure 5. – in...
Page 6: - D
2 i nstallation b lue h eat - d odge r am 2500 / 3500 6 – pull main blower control harness (3) and timer harness (1) through grommet (2) in footwell area. Refer to figure 8. – route main blower control harness (3) under dash to the blower motor (4). The blower motor (4) is located below the glove bo...
Page 7: - D
B lue h eat - d odge r am 2500 / 3500 2 i nstallation 7 positive blower wire 1. Connect the red wire (3) to the vehicle side of the positive wire (4). Refer to figure 12. 2. Connect the black wire (2) to the blower motor side of the positive wire (1). Negative blower wire 1. Connect the blue wire (7...
Page 8: - D
2 i nstallation b lue h eat - d odge r am 2500 / 3500 8 timer installation (general instructions) note: before installing the timer, please confirm the installation site with your customer. – after selecting a site for the timer, temporarily apply the timer mounting template. Refer to figure 15 for ...
Page 9: - D
B lue h eat - d odge r am 2500 / 3500 2 i nstallation 9 recommended standpipe location - 5.9l diesel (spacer required) – position the fuel sending unit spacer (3) in the slot identified in figure 18. Use the spacer as a template to mark the hole location for standpipe installation. Remove spacer bef...
Page 10: - D
2 i nstallation b lue h eat - d odge r am 2500 / 3500 10 fuel standpipe instructions - 3500 (hemi) – bend standpipe (1) 90 degrees as shown in figure 21. Note: use the slotted tube molded into the side of the sending unit to secure the standpipe away from the fuel level float. – insert standpipe (1)...
Page 11: - D
B lue h eat - d odge r am 2500 / 3500 2 i nstallation 11 fuel pump installation - diesel – install fuel pump (5) on vehicle frame with hardware provided in kit. Refer to figure 25 for mounting location. – install rubber fuel line adapter (3) on inlet side of fuel pump (5) and secure with clamp (4). ...
Page 12: - D
2 i nstallation b lue h eat - d odge r am 2500 / 3500 12 – route the fuel line (1) along fuel pump harness (2) and vehicle lines toward the engine compartment. Refer to figure 29. – use nylon wire ties to secure fuel line (1) and fuel pump harness (2) to frame rail. Refer to figure 30. – route the f...
Page 13: - D
B lue h eat - d odge r am 2500 / 3500 2 i nstallation 13 – remove knock out from top of heater (5) and install the combustion air silencer clamp (3). Refer to figure 33. – install combustion air intake tube (2) on heater and secure with clamp (1). – thread combustion air silencer (4) into combustion...
Page 14: - D
2 i nstallation b lue h eat - d odge r am 2500 / 3500 14 – secure heater support bracket (3) to the frame / bumper mounting bolt with nut (2) provided. Refer to figure 37. – tighten nut securing heater support bracket (3) to ejot stud(1). Fuel and electrical connections at heater – connect heater co...
Page 15: - D
B lue h eat - d odge r am 2500 / 3500 2 i nstallation 15 – to prevent coolant loss, clamp off coolant hose (1) going to heater core. See figure 41. – cut vehicle coolant hose (1) coming from engine block (2) in two places. – connect heater inlet hose (3) to coolant hose (1) from engine block with co...
Page 16: - D
2 i nstallation b lue h eat - d odge r am 2500 / 3500 16 exhaust – install 90 degree exhaust elbow (5) onto heater (1) and secure with clamp (6). Refer to figure 45. – cut exhaust tube (3) to a length of 22.8cm (9 inches). – connect exhaust tube (3) to 90 degree elbow (5) and secure with clamp (4). ...
Page 17: - D
B lue h eat - d odge r am 2500 / 3500 2 i nstallation 17 final inspection and initial start-up final inspection inspect installation for: • loose fasteners. • exhaust system routing and clamp tightness. • combustion air intake tube routing and clamp tightness. • loose coolant line clamps. • pinched ...
Page 18: - D
2 i nstallation b lue h eat - d odge r am 2500 / 3500 18 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 de...
Page 19: - D
B lue h eat - d odge r am 2500 / 3500 2 i nstallation 19 caution diagnostics equipment is intended for use by webasto trained personnel at authorized webasto distributor, dealer and end user service facilities. A pc diagnostic interface kit for the blueheat is available that allows for more thorough...
Page 20: - D
2 i nstallation b lue h eat - d odge r am 2500 / 3500 20 heater harness schematic - heater control portion.
Page 21: - D
B lue h eat - d odge r am 2500 / 3500 2 i nstallation 21 heater harness schematic - blower control portion.
Page 22: - D
2 i nstallation b lue h eat - d odge r am 2500 / 3500 22 heater plumbing schematic - inline method.
Page 24
Webasto product n.A., inc. Technical assistance hotline usa: (800) 555-4518 canada: (800) 667-8900 www.Webasto.Us www.Techwebasto.Com org. 10/2002 rev. 10/2004 p/n 5000681b.