Webasto BlueHeat Installation instructions manual - - 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-binding installation instructions apply to the vehicles listed on the front cover of this installation document
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” Thermo Top
must be followed. The appropriate 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!
Foreword
Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Heater Installation Site . . . . . . . . . . . . . . . . . . . . . . 3
Vehicle Preparations . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation
Electrical Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Blower Connection . . . . . . . . . . . . . . . . . . . . . . . . . 6
Timer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Integration into Fuel System . . . . . . . . . . . . . . . . . . 8
Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . .12
Integration into Coolant System . . . . . . . . . . . . . . .14
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Power Connection . . . . . . . . . . . . . . . . . . . . . . . . .16
Concluding Work . . . . . . . . . . . . . . . . . . . . . . . . . .16
Final Inspection and Initial Start-up . . . . . . . . . . . . .17
Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .18
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . .20
Coolant Schematic . . . . . . . . . . . . . . . . . . . . . . . . .22
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
3/8” Drive Ratchet
3/8” Drive 12 inch extension
13 mm socket, 3/8” drive
15 mm socket, 3/8” drive
17 mm socket, 3/8” drive
10 mm combination wrench
8 mm nut driver
Phillips #2 screwdriver
Combination side-cut/crimping pliers
Hose clamping pliers
Hose cutting pliers
Drill
2.5 mm (3/32 in.) drill bit
8 mm (5/16 in.) drill bit
10 mm (25/64 in.) drill bit
Hacksaw
Utility Knife
Mechanic’s wire - 2 feet
Hoisting equipment and safety stands
Vehicle manufacturer’s service reference manual
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.
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