Webasto HL 90 Owner's Manual - page 35
HL 90
9 Repair
905
9.2.6 Drive, Disassembly and Assembly
The disassembly of the drive is broken down into two
subjects:
– heating air supply/ electrical components
– combustion air supply / fuel ducting / motor
9.2.6.1 Heating Air Supply / Electrical Components,
Disassembly
The following steps should be performed with the heater
fully assembled.
1. For removal of cap (1, Fig. 902) remove screw (14)
and tooth washers (13) as required.
2. Using two levers (wide blade screw drivers, etc.) lever
plastic rotor (2) off from motor shaft by pushing
against orifice plate (4). Remove orifice plate and
spacer ring (5) by removing screws (3).
NOTE
When disassembling and disconnecting wiring and
connectors make sure to observe wiring arrangement,
see Fig. 902.
3. Loosen screws (15) and remove glow plug resistor
(18), locking ring (16) and washer (17).
4. Remove screw (12), tooth washer (11) and washer
(10).
5. Disconnect blade terminal from electrical connectors
(9 and 25). Check condition of grommet (8) and
replace as necessary.
6. Disconnect electrical connectors from resistor (7) and
remove resistor.
9.2.6.2 Combustion Air Supply / Fuel Ducting / Motor,
Disassembly
1. Remove cap nut (30), washer (31) and displacer (32).
2. Withdraw atomiser assembly (29).
3. Remove screws (33) and fuel line (34).
4. Remove screws (28).
5. Carefully pull bypass fan (27) out of air intake housing
(24).
CAUTION
Remove bypass fan by a slight axial pull on shaft.
Remove major contamination on edge zone to air intake
housing and slightly grease as required.
6. Withdraw one half of clutch (23); remove round cord
ring (26) and discard.
7. Remove O-ring (35) from air intake housing and
discard.
8. Pull other half of clutch (23) from motor shaft.
9. Remove screws (21) and separate air intake housing
(24) from motor (6).
10. Remove O-ring (22) and discard.
11. Perform procedures on components after
disassembly (refer to 9.1.1).
CAUTION
Clean bypass fan with pressurized air only.
9.2.6.3 Assembly
1. Position new O-ring (22, Fig. 902) on air intake
housing for assembly.
2. Assemble air intake housing (24) and motor (6) with
screws (21).
3. Slide half of clutch (23) onto motor shaft in air intake
housing (24).
4. Position new O-ring (35) at fuel transfer point in air
intake housing.
5. Position new round cord ring (26) in bypass fan (27).
6. Slide other half of clutch (23) onto shaft in bypass
fan (27).
NOTE
Fuel line must be aligned with fuel transfer point (O-ring);
clutch (23) must also engage.
7. Assemble bypass fan (27) and air intake housing (24)
with screws (28). Torque screws to 4 Nm.
8. Secure fuel line (34) in bypass fan (27) with screws
(33) torqued to 1.5 Nm.
9. Slide atomiser assembly (29) onto shaft until arrested
by drive pin.
10. Slide displacer (32) onto shaft and secure with washer
(31) and cap nut (30). Torque cap nut to 2.5 Nm.
11. Mount resistor (7) with screw (12), tooth washer (11)
and washer (10). Torque screw to 2 Nm.
12. Connect electrical connectors to resistor (7) (refer to
Section 7 as required).
NOTE
Torque for cap screws and sheet metal screws is
5.5 ± 0.5 Nm.
13. Secure glow plug resistors (18) with screws (15).
No locking rings (16) and washers (17) when sheet
metal screws are in use.
14. Slide on grommet (8) at wiring connect points of
electrical connectors (9 and 25); reconnect cable
wires to relevant connectors to restore proper
electrical functions (refer to Section 7 as required).
15. Locate spacer ring (5) and orifice plate (4) for
assembly so that spacer ring is centered on fan of
motor (6). There is no spacer ring (5) if plastic orifice
plate is in use.
16. Secure orifice plate (4) and spacer ring (5) with
screws (3) and torque to 5.5 ± 0.5 Nm. Locate tooth
washers (37) between orifice plate (plastic) and
screw (3).
17. Press rotor (2) onto shaft until seated against stop.