Webasto HL 90 Owner's Manual - page 33
HL 90
9 Repair
903
9.2.2 Glow Plug, Replacement
9.2.2.1 Removal
1. Remove knurled nut from glow plug.
2. Withdraw cable and isolator.
3. Unscrew glow plug (1, Fig. 901) and remove.
4. Perform procedures on components after disassembly
(refer to 9.1.1).
9.2.2.2 Installation
1. Apply high temperature grease (Copaslip) to thread
of glow plug.
2. Manually screw glow plug (1, Fig. 901) in and tighten
with 20 ± 2.0 Nm.
3. Bring cable and isolator in assembly position as
shown in Fig. 901, Detail A and secure with knurled
nut.
4. Tighten knurled nut with 2.0 ± 0.5 Nm.
9.2.3 Flame Sensor, Replacement
9.2.3.1 Removal
1. Disconnect electrical connection to flame sensor.
2. Remove spring (7, Fig. 901) from flame sensor (8) and
withdraw flame sensor.
3. Unscrew flame sensor receptacle (9) and remove.
4. Remove grommet (10) and discard.
5. In counterlight visually check quartz glass rod of flame
sensor receptacle for transparency.
6. Perform procedures on components after disassembly
(refer to 9.1.1).
9.2.3.2 Installation
1. Locate new grommet (10, Fig. 901) flush in installation
position.
2. Apply high temperature grease (Copaslip) to thread of
flame sensor receptacle.
3. Manually screw flame sensor receptacle in place and
torque with 20 ± 2.0 Nm.
4. Plug on flame sensor (8) and secure with retaining
clip (7).
5. Make electrical connection of flame sensor to wiring
harness.
9.2.4 Temperature Limiter, Replacement
9.2.4.1 Removal
1. Disconnect electrical connection to temperature limit-
er.
2. Slide silicone cap (5, Fig. 901) up enough to make
hexagon of temperature limiter (4) accessible.
3. Unscrew temperature limiter and remove.
4. Perform procedures on components after disassembly
(refer to 9.1.1).
9.2.4.2 Installation
1. Screw temperature sensor (4, Fig. 901) in by hand
and tighten with 0.8 ± 0.2 Nm.
2. Form-fit silicone cap (5).
3. Make electrical connection of temperature limiter to
wiring harness.
9.2.5 Drive, Replacement
9.2.5.1 Removal
1. Remove control unit (see 9.2.1.1).
2. Disconnect electrical connector (9 and 25, Fig. 902)
and carefully push into half case together with
grommet (8).
3. Remove screws (12 and 16, Fig. 901) and spring
washers (17). Slightly widen half case and slide off
over air intake pipe.
4. Remove screws (19, Fig. 902) and lock washers (20).
5. Withdraw drive from heat exchanger and remove.
6. Perform procedures on components after disassembly
(refer to 9.1.1) or continue to disassemble drive
(see 9.2.6).
9.2.5.2 Installation
1. Apply vaseline to O-ring (22, Fig. 902).
2. Bring drive with heat exchanger in assembly position
secure with screws (19, Fig. 902) and lock washers
(20).
3. Tighten screws with 5.5 ± 0.5 Nm.
4. Slightly widen half case (15, Fig. 901), route electrical
connector (9 and 25, Fig. 902) with cable to exterior
and push grommet (8) into opening for proper fit in
place.
5. Position half case (15, Fig. 901) for assembly and
secure with screws (12).
6. Secure half case (15) with screws (16) and spring
washers (17).
7. Tighten screws (12 and 16) with 2.5 ± 0.2 Nm.
8. Secure cap (1, Fig. 902) with screws (14) and tooth
washers (13).
9. Tighten screws (14) with 2.5 ± 0.2 Nm.
10. Install control unit (see 9.2.1.2).