Coolant Heater

Thermo Top Series

1
Light Duty Generic Installation
Instructions

7 2

6
3

4
5

Legend
1 Electrical Harness sockets
2 Coolant Outlet
3 Fuel Inlet
4 Exhaust
5 Coolant Inlet
6 Coolant Circulation Pump
7 Combustion Air Intake

Special Tools
– Hose Clamping pliers
– Torque Wrench

Foreword
1.1 Scope and Purpose - - - - - - - - - - - - - - - - - 5 4.5 Integration into the Fuel System - - - - - - -19
1.2 General Safety / Installation Instructions- - - 5 5 Combustion Air Supply- - - - - - - - - - - - - -21
1.3 Symbol Identification - - - - - - - - - - - - - - - 6 5.1 Air Intake Silencer Installation - - - - - - - - -21
1.4 General References - - - - - - - - - - - - - - - - 7 6 Exhaust System - - - - - - - - - - - - - - - - - - -22
1.5 Preparation - - - - - - - - - - - - - - - - - - - - - - 7 7 Integration into the Coolant System - - - - -22
Installation 7.1 Repositioning the Circulation Pump - - - - -23
2 Electrical Overview - - - - - - - - - - - - - - - - - 8 8 Power and Ground Connections - - - - - - -24
2.2 Electrical Harness - - - - - - - - - - - - - - - - - - 9 8.1 GroundConnection - - - - - - - - - - - - - - - -24
2.3 Fuse Tap Connection - Relay K-1 - - - - - - - 9 8.2 Power Connection - - - - - - - - - - - - - - - -24
2.4 Routing Harnesses Through Bulkhead - - - - 9 9 Final Inspection, Initial Start-up and
2.5 Timer Installation - - - - - - - - - - - - - - - - - 10 Concluding Work - - - - - - - - - - - - - - - -25
2.6 Integration into the Blower System - - - - - 10 9.1 Final Inspection (use installation checklist) -25
3 Heater Mounting - - - - - - - - - - - - - - - - - 12 9.2 Initial Start-up - - - - - - - - - - - - - - - - - - - -28
3.1 Recommended Locations- - - - - - - - - - - 12 9.3 Concluding Work - - - - - - - - - - - - - - - - -28
4 Fuel System - - - - - - - - - - - - - - - - - - - - - 16 10 Heater Lockout Reset Procedure - - - - - - -29
4.1 Fuel Extraction - - - - - - - - - - - - - - - - - - - 16 Electrical Harness Schematic - Part 1 - - - - - - - -30
4.2 Fuel Supply - - - - - - - - - - - - - - - - - - - - - 18 Electrical Harness Schematic - Part 2 - - - - - - - -31
4.3 Fuel Lines - - - - - - - - - - - - - - - - - - - - - 18 Heater Plumbing Schematic - Inline Method - -32
4.4 Fuel Pump Installation - - - - - - - - - - - - - - 19 Programming the 24 Hour Digital Timer- - - - - -33

DOC P/N 5000778C KIT P/N 5000777B Printed in USA Webasto Thermo & Comfort N.A., Inc.

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 • Webasto heating and cooling systems require qualified and/or professional instal-
lation and repair technicians. Warranty shall be void if not installed by a certified
or trained installer/repair technician who has successfully completed the factory
training course for installation and repair of Webasto heating and cooling systems,
and has been provided with the technical information, tools and equipment
required to properly complete the necessary installation/repairs.
• Only genuine Webasto parts may be used. See also Webasto air and water heat-
ers accessories catalogue.
• Product produces temperatures high enough to ignite surrounding combustible
materials such as inflammable liquids, gases, vapor, and other combustible matter.
The heater must be switched off when loading or unloading inflammable materi-
als to prevent the risk of explosion.
• 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.
• ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
• Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel or by improper installation.

If there are any questions regarding the installation or maintenance of this product,
please call technical support at 1-800-860-7866.

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 Thermo Top C

1 Foreword
Webasto heating and cooling systems require qualified and/or professional installation and repair technicians.
Warranty shall be void if not installed by a certified or trained installer/repair technician who has successfully
completed the factory training course for installation and repair of Webasto heating and cooling systems, and
has been provided with the technical information, tools and equipment required to properly complete the
necessary installation/repairs.
Any use, operation, installation, modification or application of the product not described in Webasto manuals,
or subjecting the product to extreme or unusual conditions beyond the limits of specified performance
characteristics is misuse of the product.
Failure to comply with all installation instructions is a misuse of Webasto products. The same applies for repairs
without using genuine Webasto service parts. This will void the coolant heaters “official Marks of Conformity.”

1.1 Scope and Purpose

These installation instructions are intended to support Webasto trained and authorized distributors and dealers
in the installation of the Thermo Top series Coolant Heaters. These instructions are not intended for use by
untrained or unauthorized personnel.

The directives in the “master reference manual” and “operating manual” for the Thermo Top series heater
must be followed. Acknowledged 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!

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.

1.2 General Safety/Installation Instructions

– Webasto heaters must be switched “off” when re-fueling at filling stations and/or while loading or
unloading flammable materials for transport, to prevent the risk of explosion. Please review owner’s
manual for safety and use instructions.
– The heater must not be installed in the passenger compartments of the vehicle.
– Extracting combustion air from the passenger compartment of the vehicle is not permissible under any
circumstance.
– Exhaust pipes must be routed so that exhaust fumes will not penetrate into the vehicle’s interior.
– Do not route exhaust components within 100 mm (4 inches) of flammable materials such as fuel system
components, polyurethane or similar foam insulation, styrene sheet installation, wood and paper
products, carpet, glycol reservoirs, coolant lines, brake lines, electrical wiring, etc.
– The operational state of the heater, i.e. an indication “on” or “off”, must be clearly visible to the operator.
– The coolant heater may only be operated within the specified voltage range designated.
– The coolant heater may only be operated with the specified fuel as recommended by the vehicle
manufacture.
– The following important regulations must be adhered to when routing fuel lines:
• Fuel lines are to be installed in such a way that they remain unaffected by torsional stresses created by
vehicle and engine movement.
• Fuel lines be securely fastened to the vehicle every 12 inches (30 cm) or less along the total length from
heater to fuel tank.
• Fuel-carrying components are to be protected against excessive heat and are to be installed so that any
drippings or evaporating fuel can neither accumulate nor be ignited by hot components or electrical
equipment.
• In buses, fuel lines are not to be located in the passenger area or in the driver’s compartment. Fuel sup-
ply must not be by means of gravity or pressurization of the fuel tank.
• The fuel tank must be equipped with a vent cap or ventilated in another way (vent line)

3
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 Thermo Top C

1.3 Symbol Identification

1.3.1 Symbols that define sections in manual

Mechanical Preparation Fuel

Electrical Exhaust

Coolant Combustion Air Intake

General Symbol Descriptions

Warning Refer to Webasto or Manufacturer Manual

Caution Attention

Flammable or Combustible Line of Sight/Item Location on Vehicle

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1.4 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 (opened fuel hose) to sharp edges.

1.5 Preparation
1.5.1 Heater Kit
– Verify and identify all contents of kit.

1.5.2 Vehicle
– Verify fuel content in tank.

CAUTION
For reasons of safety due to possible fuel spillage, it is recommended that there be no more than 1/2 tank of fuel
present. If fuel quantity is greater than 1/2 of capacity, make provisions to reduce quantity of fuel.
– Disconnect negative terminal of vehicle battery(s).
– Protect vehicle fenders, panels and interior with covers

5
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 Thermo Top C

2 Electrical Overview
ATTENTION
Ensure wiring and wiring harnesses are securely fastened to the vehicle. If not described differently, securing of
wiring is done with cable ties to the vehicle’s own wiring harnesses.

2.1 Universal Electrical Harness Description

Legend for Figure 1 1 2 3

1 Fuse holder and fuses

2 Resistor - HVAC blower control 26
3 Relay K1 - HVAC control 25 4
4 Relay K2 - HVAC control 24 5
5 18 GA green - “ON” signal from relay K1 and K2 to
relay K3, pin 86
6 18 GA blue - Ignition “ON” signal source 6
7 Main heater harness
8 Blower control harness - Positive side 23
9 10 GA black - HVAC control switch circuit, splice to
blower motor positive circuit (motor side) 22
10 10 GA red - HVAC control switch circuit, splice to 21
blower motor positive circuit (control side)
11 18 GA green - “ON” signal from relay K1 and K2 to 7
relay K3, pin 86, use when relay K3 is mounted near 20
HVAC blower motor (same circuit as item 5)
12 Blower control harness - Negative side
Harness is wire tied to main harness for shipping 19
purposes only, cut wire tie to separate negative
side blower harness from main harness
13 10 GA white - HVAC control switch circuit,
8
splice to blower motor negative circuit (motor
side) 10
14 10 GA blue - HVAC control switch circuit, splice 11
to blower motor negative circuit (control side) 18 9
15 10 GA brown - Connect to vehicle ground point
when relay K3 is mounted near HVAC blower motor
16 18 GA green - Relay K3, pin 86 (connects to “ON”
signal 18 GA green from relay K1 and K2). See items
5 and 11.
12
17 Relay K3 - HVAC control (typically mounted near
HVAC blower motor)
18 18 GA blue and brown - Fuel metering pump 13
harness
14
19 20 GA black, red and brown - Timer harness
20 18 GA violet - “Vent Mode” for optional remote
control 17 16 15 Fig. 1
21 10 GA red - Battery positive
22 10 GA brown - Battery negative or ground point
23 Main power harness
24 18 GA yellow - Diagnostic connection
25 18 GA orange - Supplemental heating option
26 10 GA brown - Optional ground connection for relay
K3 when K3 is mounted with relay K1 and K2

6
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2.2 Electrical Harness

ATTENTION
2
Remove cable tie holding the negative-side blower
1
control harness from the main harness and set aside.
7 3 This harness will be mounted near the vehicle blower
4 motor.
6 5 Mount heater electrical components on supplied
mounting bracket with hardware provided. Secure
mounting bracket to vehicle in an appropriate location
(away from plastic parts), keeping in mind the proximity
of the vehicle battery and bulkhead pass-through
Fig. 2 grommet.
– (1) Nut 10-32 used as a spacer
– (2) Bulkhead brace
– (3) Screw M3x10, Nut M3 (2ea.)
– (4) Pan head screw 10-32x5/8”, Nut 10-32 (3ea.)
– (5) Fuse holder
– (6) Relays K1 and K2
– (7) Mounting bracket

1 2
2.3 Fuse Tap Connection - Relay K-1
CAUTION
Tap into the “fused” output side of the selected fuse.
Fuse must remain hot with the ignition in the “ON”
position only.
ATTENTION
•The blue fuse tap wire signals the Webasto heater of
an ignition cycle, returning vehicle blower control to
the driver’s discretion.
•You may need to route the fuse tap wire into the inte-
rior of the vehicle. Refer to Routing Harness Through
Bulkhead.
Fig. 3
Route blue fuse tap wire from relay K-1, to the
underhood or interior fuse/relay center.
– (1) Underhood or interior fuse/relay center
– (2) Fuse tap

2.4 Routing Harnesses Through Bulkhead

1 2
CAUTION
Check behind bulkhead for obstructions before drilling
hole.
ATTENTION
Seal bulkhead grommet with silicone sealant after
routing harnesses.
Cut a 13 mm (1/2 in.) slit in bulkhead grommet.
Route blower and timer control harnesses through
grommet in bulkhead into the interior of the vehicle.
– (1) Vehicle bulkhead grommet
Fig. 4
– (2) Blower and timer control harnesses

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2.5 Timer Installation

CAUTION
Check behind panels for obstructions before drilling
holes.
ATTENTION
Before installing the timer, please confirm the
installation location with the customer.
Affix supplied template to panel. Drill 10 mm (25/64 in.)
and 2.5 mm (3/32 in.) holes where indicated on template.
Figure 5 shows a translated sample of the template
supplied. Fig. 5

ATTENTION 1
Do not over tighten mounting screw.
Carefully align timer harness plug with socket on rear of
timer and push into socket until seated.
Place the timer into position and secure with screw
provided. Tighten screw until the timer with foam
cushion is firmly seated against panel. Install cover over
screw.
– (1) Timer

Example of Timer Mounting Fig. 6

2.6 Integration into the blower System

Route positive-side blower harness (black and red wires)

over to blower motor area.
Mount negative-side blower harness (blue and white 1
wires) and relay in vicinity of HVAC blower.
2
– (1) Chassis ground wire
– (2) Relay K-3 of negative-side harness)

Fig. 7
2.6.1 HVAC Blower Motor Location
1
ATTENTION
The blower motor is usually located under the dash on
the passenger side of the vehicle or attached to the
bulkhead under the hood.
Disconnect the blower motor connector from the blower
motor. Using a test light or similar tool identify the power
and ground wires.
Cut blower control wires at a point approximately 50 mm
(2 in.) from the connector end and make connections as 2
described (see para. 2.6.2.).
Fig. 8
– (1) HVAC blower motor
– (2) HVAC blower motor connector

8
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2.6.2 3-Relay HVAC Harness Connec-

Webasto Vehicle
tions
NOTE:
It is permissible to cut excess length from
Webasto HVAC wiring harnesses to fit the
application.
Cut motor wires where indicated by “X”
– (1) Chassis ground
– (2) Splice green wire to green wire
– (3) Strip and crimp red wire to controller
side blower control positive wire
3 – (4) Strip and crimp black wire to motor
side blower control positive wire
– (5) Strip and crimp white wire to motor
side blower control negative wire
4 – (6) Strip and crimp blue wire to controller
side blower control negative wire

CAUTION
Check your wiring! Ensure that all
connections have been done in accordance
with the wiring diagram shown (Fig. 9).
5 Sensitive electronic controls can be
damaged if wired incorrectly!

Secure HVAC blower control wiring to

6 vehicle structures with nylon wire ties.
2
(Image not available)
NOTE:
1 Complete heater harness schematics are
Fig. 9 included on page 24 and 25 of this manual.

Legend for Figure 9

A From Webasto Heater X1
B 12 VDC Ignition ‘On’ Fuse Tap
C HVAC Control Module
M HVAC Blower Motor
X Cut wire at 50 mm (2 in.) from motor
F1 Fuse - Blower Circuit 25 Amp.
K1 Relay - Ignition ‘On’ Interrupt
K2 Relay - Positive Side of Blower Motor Circuit
K3 Relay - Negative Side of Blower Motor Circuit
R1 Resistor - Blower Speed Control
30 Battery Positive (Constant Power)
15 Ignition (Switched Power)
31 Battery Negative (Chassis Ground)

9
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 Thermo Top C

3 Heater Mounting
90° 90°

3.1 Recommended Locations

Refer to Figure 10 for the location of heater
connections and dimensions, this will aid in
determining the best mounting site.
CAUTION
The heater must not be installed in the
immediate vicinity of hot vehicle parts or
in the direct splash-water area of the
wheels.
ATTENTION
Ensure to maintain sufficient clearance
between the heater and moving vehicle
components under all driving conditions,
i.e. vehicle suspension, engine, etc.
Consider how exposure to extreme Fig. 10
elements will affect heater operation, i.e.
rocks, mud, snow, etc.
Recommended heater locations: Engine Compartment, Front Fenders (above splash shields), frame rail, etc...
ATTENTION
The coolant pump on the Webasto heater
is not of the self-priming type. To ensure
automatic venting of the heater and
circulation pump mount the heater in the
lowest protected area possible.

CAUTION
The opening of the coolant connection
pipes must never point in a downward
direction in any installation position.
Figure 11 identifies the correct mounting
positions for the proper operation of the
Webasto heater.

Fig. 11

3.1.1 Sample Heater Installation (Chrysler 300 C)

90° 90°
CAUTION
Sheet metal screws must never be used to secure
heater mounting brackets to the vehicle.
ATTENTION
• The heater mounting brackets must have a minimum
of three anchor points. 1 2
• Remove burs and sharp edges from heater mounting
bracket after modification.
Cut supplied mounting bracket as shown in figure 12.
Bend mounting bracket “ears” inward 90° as shown.
Fig. 12
– (1) Heater mounting bracket (Front View)
– (2) Heater mounting bracket (Side View)

10
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2
ATTENTION
Observe torque specifications.
Install heater mounting bracket with three EJOT screws.
1 Tighten EJOT screws to 10 Nm (88.5 lb.-in.).
– (1) Heater mounting bracket
– (2) EJOT screws

Fig. 13

1 2
Drill a 7mm (17/64 in.) hole through front bumper
32mm
support as shown in Figure 14.
Locate the 7mm (17/64 in.) hole 13mm (0.5 in.) in from
the end and 32mm (1.25 in.) in from the front.
– (1) Washer bottle
– (2) Front bumper support
13mm

Fig. 14

1 2
Mount heater to front bumper support with hardware
provided. See Figure 15.
– (1) Webasto heater
– (2) Front bumper support
– (3) Mounting hardware

Fig. 15

1 2
Install rear heater support bracket on heater with two
EJOT screws.
3 ATTENTION.
Use the rear support bracket to locate and drill a 7mm
(17/64 in.) mounting hole for bracket installation.
Secure rear support bracket to vehicle with M6x20 bolt
and nut.
– (1) Washer bottle
4 – (2) M6x20 bolt and nut
– (3) Rear heater support bracket
Fig. 16 – (4) EJOT screws

11
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 Thermo Top C

3.1.2 Sample Heater Installation (Ford F-150)

ATTENTION
The Webasto Auxiliary Coolant Heater is to be installed
behind left front head lamp assembly affixed to the 1
front core support as shown in Figure 17.
– (1) Webasto Coolant Heater and Bracket.

Fig. 17

1
ATTENTION
Bend heater mounting bracket as shown in Figures 18
and 21. 2
Using three self tapping EJOT screws, install heater
mounting bracket to heater as shown.
3
– (1) Webasto Auxiliary Heater
– (2) EJOT Screw
– (3) Heater Mounting Bracket

Fig. 18

ATTENTION
With head lamp removed, temporarily align heater and
heater bracket in place ensuring clearance from
surrounding vehicle structure. Adjust or bend “ears” on
heater mounting bracket to conform to mounting
location. Mark all four hole locations with marker. See
Figures 19 and 20.

Fig. 19

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ATTENTION
Remove heater and drill the four previously marked
hole locations using a 6.5 mm (1/4 in.) bit.

Fig. 20

1 2
ATTENTION
Prior to heater installation, the following components
must be mounted to heater:
4 – (1) Combustion Air Intake Tube
– (2) Heater Bracket
– (3) Coolant Inlet Hose
5 – (4) Coolant Outlet Hose
– (5) Straight Fuel Line Connector
– (6) Exhaust Tube
6
3 Fig. 21

1
ATTENTION
Top view of heater installed in vehicle.
– (1) Webasto Auxiliary Coolant Heater

Fig. 22

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 Thermo Top C

4 Fuel system
4.1 Fuel Extraction
4.1.1 Standpipe Installation Position
The installation position of the fuel extractor is
shown in Figure 23 and depends on the
relevant vehicle-specific installation conditions.

General instructions The following details are

supplied in the installation documentation for
the specific vehicle:
- Position of the hole in the tank fitting Fig. 23
- Cut the fuel extractor to length
- Shape and bend the fuel extractor
- Vehicle-specific installation instructions
If you do not have any installation documentation for the specific vehicle, find a suitable position in the tank
fitting. The fuel extractor must end 5 - 8 mm above the base of the tank after it has been shaped and cut to
length. It must not interfere with the function and stability of the tank fitting.

IMPORTANT To ensure that the tank fitting it perfectly sealed, its surface areas at the top and bottom, near the
fuel extractor, must be parallel to each other and completely flat (no embossing, labelling, etc.). The parts must
be clean and must not come into contact with fuel or grease before installation. Do not lose the sealing ring in
the fuel extractor's groove.

NOTE These binding installation instructions apply to the above fuel extractor as long as technical modifications
to the vehicle do not adversely affect the installation. Depending on the version of and equipment in the vehicle
it may be necessary to change these installation instructions. In any event, however, you must comply with the
appropriate technical rules and regulations for the installation work. Failure to follow these installation
instructions and their content will result in the refusal of all liability on the part of Webasto. The same also
applies to repairs not carried out properly or using parts other than genuine spare parts

4.1.2

Preparations
- Drill a hole with a diameter of 6.0+0.5 mm in the
appropriate position in the tank fitting
- Remove the burr from the hole
- Bend the fuel extractor and cut it to length
- Remove the burr and chips out of the pipe (the
internal pipe diameter must not be constricted)

To install the fuel extractor

- Install the fuel extractor as shown in Figure 23,
the seal must be placed in the groove
- The tightening torque for the lock nut is 5+1 Nm
Fig. 24
To install the fuel hose
- Push the fuel hose as far as possible on to the fuel extractor port as shown in Figure 2 and secure it with a
10 mm clip
- Push the fuel line as far as possible into the fuel hose as shown in Figure 2 and secure it with a 10 mm clip

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 Thermo Top C

4.1.2 Vent Line Adapter

1
This standpipe version utilizes the fuel tank filler vent tube to access the fuel
2 supply.
The standpipe must extend into the fuel tank far enough to provide an
adequate fuel supply to the heater. Ideally, the end of the standpipe should sit
25-50 mm (1-2 in.) off the bottom of the fuel tank.
3
Legend for Figure 25
1Fuel Outlet
2Vent Tube Splice Connector
3Standpipe

Fig. 25

4.1.3 Fuel line Tee Adapter

There are various sizes and shapes of fuel line adapters available from Webasto
(see Figure 26).
CAUTION
A fuel line adapter should not be installed after the vehicle fuel pump. Fuel line
pressure from the vehicle fuel pump could overcome the Webasto heater
dosing pump, causing excessive fuel delivery to the heater.
If the heater is being installed in a vehicle equipped with a fuel injection system,
determine if the vehicle fuel pump is mounted in the fuel tank. If the fuel pump
is mounted outside of the fuel tank a fuel line adapter can be used in place of
the standpipe. This is only true when the fuel line adapter can be installed prior
to the vehicle fuel pump.
ATTENTION
Fuel should not be extracted from the vicinity of the engine (gasoline only) as
gas bubbles (vapor lock) are likely to form in the fuel line, which could cause
malfunctions in heater operation.

Fig. 26

CAUTION
A special Webasto fuel line adapter must be used for
fuel extraction from the vehicle fuel supply or return
line (see figure 27).
The fuel line adapter must be mounted so that any air or
gas bubbles that may form are automatically discharged
toward the fuel tank.
to engine
from tank

to metering pump Fig. 27

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4.2 Fuel Supply

Particulars on pressure values permitted to
prevail at the point of fuel extraction are
contained in the Table below.

TABLE 1. Permitted Pressure Values

permissible fuel at max. permissible
feed height H (m) overpressure (bar)
in the fuel line
0.00 0.2
1.00 0.11
permissible fuel at max. permissible
suction height S (m) underpressure (bar)
in the fuel tank
0.00 -0.10
0.50 -0.06
1.00 -0.02

Note: 1 bar = 14.5 psi and 1 psi = .069 bar

l1 + l2 7 m
l1 1,2 m
l2 5,8 m

Fig. 28

4.3 Fuel Lines

The special fuel line supplied in the kit is the only fuel line approved by Webasto for heater installation.
Ensure the fuel line from the metering pump to the heater is not routed in a downward pitch and is secured to the
vehicle. Fuel line mounting should be done in such a manner that the lines are protected from flying objects and
heat sources.

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ATTENTION
•Ensure the fuel lines are fully seated within the fuel line
couplers and any 90 degree bends are not buckled. Refer
to Figure 29.
•Tighten all fuel line clamps to 1.0 - 1.4 Nm (8.8 - 12.4
lb.-in.)
•Always cut Mecanyl fuel line with a sharp razor knife or
razor edged cutter. Using side cutters, scissors or similar
tools will cause a restriction inside the fuel line.

Fig. 29

4.4 Fuel Pump Installation

The fuel metering pump is a combined fuel supply,
metering, and shutoff system and is subject to certain
installation criteria (See Figures 30 and 31).
Prior to installing the metering pump ensure the
maximum pressure prevailing at the fuel extraction point
is below 0.2 bar.
Install the fuel metering pump in accordance with Figures
29 or 30.

Metering Pump DP30 (Diesel) Fig. 30

ATTENTION
The outlet side of the metering pump is located on the
same end as the electrical connector.
It is recommended that the metering pump be installed in
a location on the vehicle that stays reasonably cool,
excessive heat may cause the pump to vapor lock.
The metering pump should be mounted to the vehicle by
a sound and vibration-damping suspension (rubber
mount provided in kit).

Metering Pump DP2 (Gasoline) Fig. 31

1 4.5 Integration into the Fuel System
2
4.5.1 Typical Standpipe Installation (example
only)
ATTENTION
Figure 32 shows a fuel sender accessible from inside
the vehicle.
Remove the fuel sender from the vehicle following the
manufactures service instructions.
– (1) Under rear seat
– (2) Fuel sender

Fig. 32

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ATTENTION
1 2
When selecting a location for standpipe installation,
ensure to leave enough room for electrical connections
and float arm operation.

Drill a 5/16 in. hole through the fuel sender where

shown in Figure 32.
– (1) Fuel sender
– (2) 5/16 in. hole drilled for standpipe

4.5.2 Standpipe Assembly Fig. 33

ATTENTION
1
• The standpipe tube should terminate approxi- 2
mately 25 mm (1in.) off bottom of tank when 4
installed. 3
• Ensure standpipe does not interfere with the 4
float arm. 5
Cut standpipe (45° angle cut) to length and bend as 6
necessary. 7

– (1) Banjo bolt

– (2) Banjo fitting
– (3) Sealing washer
– (4) Fuel sender 6 Fig. 34
– (5) Flat washer
– (6) Standpipe
– (7) Locknut
1 2 3
Install fuel sender following the manufacturer’s service
instructions.
Position standpipe as desired. Tighten banjo bolt to 9
+/- 0.5 Nm (80 +/- 4.4 lb in.)
Connect fuel line to standpipe with fuel line coupler.
Route Mecanyl fuel line to fuel pump mounting
location.
– (1) Fuel line clamp
– (2) Fuel standpipe - Banjo bolt
– (3) Fuel sender (installed in tank)
1 4 Fig. 35
– (4) Fuel line coupler

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5 Combustion Air Supply

ATTENTION
• The combustion air must never be drawn from the occupant area of the vehicle. If the heater is installed in an
enclosed housing, a vent hole of at least 3 cm (1.2 in.) is required
• Ensure the combustion air intake opening on the heater is positioned to prevent the possibility of clogging due
to contamination.
Locate the combustion air intake silencer in a splash-proof area, if possible.
When the heater is installed in the vicinity of the fuel tank, combustion air intake must be from the outside of the
vehicle and the exhaust gas be discharged into the atmosphere.

5.1 Air Intake Silencer Installation

Install the air intake silencer tube onto the combustion air
intake pipe of the heater and secure with hose clamp
provided.
Screw air intake silencer into combustion air intake tube
as far as possible.
CAUTION
Ensure the air intake silencer does not come into
contact with the exhaust system.
Attach the air intake silencer at a suitable place using the
supplied mounting clip or cable tie.
Fig. 35
The mounting clip can be inserted into the top of the
heater after removing knockout or any other suitable
location by drilling a 6.5 mm (1/4 in.) hole.
Position the air intake silencer between 0° and 90° with
1 2 the silencer pointing downward.

– (1) Top of heater

– (2) Knockout for air intake silencer clip

Fig. 36

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6 Exhaust System
CAUTION
Keep exhaust tube away from heat sensitive vehicle
components.
ATTENTION
Any collection of condensation in the exhaust pipe must
be drained immediately; drill a small drain hole at the
lowest point of the exhaust pipe.
The exhaust gas pipe can have several bends if necessary
(total of 270°, smallest bending radius 50 mm or 2 in.).
The total length of the exhaust pipe should not be less Fig. 37
than 500 mm (20 in.) or more than 1000 mm (39.5 in.).

The exhaust muffler should not be installed within 200

mm (8 in.) of the heater or the intake air silencer. 6.5

The discharge opening of the exhaust pipe must not

point in the direction of travel.
Rigid pipes made of alloyed steel with a minimum wall
thickness of 1.0 mm (0.039 in.) or flexible tubes of
alloyed steel can be used for exhaust installation.
ATTENTION
Ensure all exhaust clamps are properly tightened. Check
for exhaust leaks during heater operation.
Fig. 38

7 Integration into the Coolant System

ATTENTION
• Torque hose clamps to 2.0 - 2.5 Nm (18 - 22 lb-in.)
• Avoid sharp bends and kinks when installing coolant hoses.
• The hose clamps at the heater must be mounted between the flared neck of the pipe and the heater.
• Position hose clamps in such a way to avoid cutting or damaging adjacent components.
• Ensure coolant hoses are routed at least 100 mm (4 in.) from heat generating components (exhaust, etc.)
• To ensure proper venting, route coolant hoses below coolant filler cap.
As a rule, the coolant hose supplied by Webasto should be used. If any other coolant hose is used it must conform
to DN standard 73411. Ensure coolant hoses are routed in a way that prevent kinks and allow for proper venting.
The coolant hoses should be pitched upward if possible.
ATTENTION
Clamp vehicle coolant hose with hose clamping pliers prior to cutting to prevent coolant spillage.
The coolant heater integration into the vehicle heater circuit is done in an “INLINE” fashion. Refer to Figure 39. The
heaters are to be installed in the cooling system in the flow of the vehicle’s heat exchanger.
ATTENTION
Follow the vehicle manufacture’s specifications for proper coolant mixture and type.
Ensure the coolant circuit is properly vented before operating the heater for the first time or after a coolant
change. The heater should be installed in a way to ensure static venting. Insufficient venting can result in a failure
during heater operation due to overheating.
ATTENTION
Ensure to pressure test the coolant system after heater integration.
Also see the plumbing schematic, page 26, of this manual for a general outline of the coolant circuit arrangement.

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Fig. 40

7.1 Repositioning the Circulation Pump

The circulation pump can be mounted at the location
provided on the heater or be integrated into the coolant
circuit, away from the heater.
Ensure flow through the heater is correct (coolant outlet
at the top / coolant inlet at the bottom) or the heater will
malfunction.

Fig. 41

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8 Power and Ground Connections

8.1 Ground Connection
Use existing ground point to attach the control harness
ground (brown wire).
– (1) Existing vehicle ground 1
– (2) Control harness ground

2 Fig. 42

8.2 Power Connection

Attach the control harness power lead (red wire) to the
positive stud or the battery positive post. 1
– (1) Positive stud
– (2) Power distribution center
2
IMPORTANT!
All power connections must be fused within 14” of the
battery.

Fig. 43

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9 Final Inspection Initial Start-up and Concluding Work

Connect battery ground terminal

9.1 Final Inspection

HEATER MOUNTING Complete

(Yes/No/Comments)
1 Is the heater installation safely secure / rigid?
(Ensure that all bracket bolts are tight)
2 Is there a safe clearance from heat generating
Components? (I.e. exhaust, etc...)
3 Is there sufficient clearance between heater and any
vehicle moving components under all operating
conditions? (steering cranked to extreme positions,
torqued engine, suspension, etc...)
4 Is the heater mounted in an acceptable position
according to the limitations noted in the
installation manual?
5 Is the heater installed in a protected location from
road debris and splash-water or items stored in the same area?
6 Is there a sufficient amount clearance
between the heater and the ground? (Coolant heaters only)

COOLANT SYSTEM Complete (Yes/No/

Comments)
1 Is there a safe clearance (min 4 in.) from heat generating components?
(exhaust, etc...)
2 Is there a safe clearance from sharp edges / objects?
Ensure a heat protective has been installed (if applicable)
3 Are there any kinks, sharp bends or the possibility for pinched hoses or
harnesses, cuts and rub through?
4 Have all the hose clamps been properly positioned and tightened?
5 Has the coolant system been topped off and bleed per the vehicle
manufacture’s specifications for proper mixture and type?
6 Has a pressure test been performed on the coolant system under all
operating conditions?
7 Have the coolant hoses been installed so that they are below the coolant
filler cap?
8 Has the coolant flow direction been verified?

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ELECTRICAL Complete
(Yes/No/Comments)
1 Has all wiring been safely secured away from moving components
and / or heat sources?
2 Check for proper power and ground connections.
3 Has blower motor functionality been tested (if applicable)?
4 Check for proper fuse tap connection.
5 Verify the correct fuses are in the specified locations per the
installation manual.
6 Ensure heater and vehicle fuse boxes are closed and secure. Was the
Webasto fuse block installed in a location protected from water and /
or moisture?
7 Ensure blower motor resistor (1.0Ω) is securely mounted and has
sufficient clearance from any plastic component and battery.
8 Ensure battery is mounted securely and connections are properly
tightened.
9 Ensure battery is at ? 12.2Vdc for 12V, 24.4Vdc for 24V.
FUEL SYSTEM Complete (Yes/No/
Comments)
1 Is the standpipe properly mounted in the fuel tank?
(sealed, structural integrity maintained).
2 Validate the standpipe does not interfere with function of sending
unit by checking fuel gauge for proper operation before completing
installation of tank.
3 Verify that all fuel lines are properly secured and are a safe distance
(min. 4 in.) from exhaust systems and / or moving components.
4 Check all fuel lines for leaks or kinks.
5 Check fuel line clamps for proper positioning and tightness. Ensure
fuel system is free of leaks.
6 Ensure fuel pump is securely mounted in a cool location
NOTE: Vehicle fuel tank area is generally a location with minimal
sound transfer path to vehicle interior.

EXHAUST SYSTEMS Complete

(Yes/No/Comments)
1 Is the muffler and clamps securely tightened?
2 Has muffler and exhaust tube been routed a safe distance (min. 2 in.)
from flammable material?
3 Ensure drain-holes are drilled in low bend areas of exhaust tube.
4 Ensure exhaust is venting a safe distance from any vehicle interior
openings.
5 Ensure exhaust is venting in the direction that will not cause back
pressure while driving.

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COMBUSTION AIR INTAKE Complete

(Yes/No/Comments)
1 Is the combustion air intake drawing fresh air from a non-turbulent
location? (i.e. not in direction of travel)
2 Ensure air intake system is securely fastened.
HEATER FUNCTION Complete (Yes/No/
Comments)
1 Ensure heater starts and runs for a minimum of 20 minutes.
2 Ensure vehicle blower turns “ON”.
3 Ensure warm air is blown out of interior vents after blower is
activated.
4
Ensure timer (control device) is functioning.
5 Check and Modify CO2 setting as needed based on altitude (will the
heater “live” or spend a lot of time above XXXXXX Feet)
(See service manual for instructions to make adjustment)

COSMETICS Complete (Yes/No/

Comments)
1 Has the vehicle interior, engine compartment, trunk & glove
compartment been inspected for cleanliness after installation.
2 Has user manual placed in glove box?
3 Is the vehicle clock time correct after disconnecting the battery?

If you have any questions, contact our technical support team at (800) 860-7866 or via email at:
[email protected].

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9.2 Initial Start-up

WEBASTO HEATERS MUST BE SWITCHED “OFF” WHEN RE-FUELING AT
FILLING STATIONS AND/OR WHILE LOADING OR UNLOADING FLAMMABLE
DANGER MATERIALS FOR TRANSPORT, TO PREVENT THE RISK OF EXPLOSION. PLEASE
REVIEW OWNER’S MANUAL FOR SAFETY AND USE INSTRUCTIONS.
ATTENTION
The fan speed control knob has to be between low and maximum for blower operation while the Webasto
heater is on. The position of the control knob does not change the speed of the blower while the heater is on.
1 Set interior temperature control to maximum heat position (hot), fan speed between low and maximum, and
switch to defrost mode.
2 Start the vehicle engine and run on fast idle for 5 minutes to purge any remaining air from the Webasto
heater and coolant system. While the engine is running check:
• Hose connections for leaks.
• Coolant level in expansion tank. (Add coolant as needed)
3 Switch off the engine.
ATTENTION
More than one start-up attempt of the heater may be required to purge air from fuel system before heater will
start. Cycle heater Off and On after each failed start attempt until heater starts successfully. After 3 consecutive
unsuccessful start attempts, the Webasto control unit enters into heater lockout.
See Heater Lockout section for reset instructions.
4 Switch on the Webasto heater by means of the instant heat button on timer and check:
• Timer panel and instant heat indicator illuminates.
• Circulating pump in operation.
• Initiation of start-up sequence.
• Successful start-up and operation.
ATTENTION
The vehicle blower motor should come on after 5 minutes of heater operation, depending on outside air
temperatures.
5 Allow heater to run for 20 minutes or until coolant is heated to temperature. Re-tighten all hose clamps.
ATTENTION
Engine coolant temperature gauge may read lower than actual Webasto heater output temperature.
This is due to the location of the temperature gauge sensor on engine.

9.3 Concluding Work

– Check that all hose lines, hose clamps, pipe clips and electrical connections are secure. Secure all loose lines
and cables with nylon cable ties.
– Spray the heater components and electrical connections with an anti-corrosive wax coating.
– Install all vehicle parts, panels and components removed during heater installation.

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10 Heater Lockout Reset Procedure

The control unit continuously monitors the heater operation. The control unit identifies errors on individual
heater components and faults during operation. Should the control unit experience component errors and
operational faults, the heater may be shut down.

Causes:

The heater is shut down (fault lock-out) if:

– No or incorrect start
– Temperature sensor defective
– Overheating sensor interrupt or short circuit
– Overheating sensor installed incorrectly
– Ceramic glow pin interrupt or short circuit
– Fan motor overload or blocked or short circuit or interrupt
– Error in the fuel metering pump or circuit
– Under voltage or over voltage for longer than 20 seconds.
– Control unit defective
– Overheating
Effects:

The fuel supply is stopped if the heater overheats.

The heater continues to run in the same way as if it is switched off manually.
After the heater stops the control unit may set in fault lock-out mode.

Heater Lock out Reset Procedure:

1. Using switch or standard timer control, turn heater on
2. Remove the main power connection to heater from battery or pull fuse for a minimum of 20 seconds.
3. Using switch or standard timer control, turn the heater off.
4. Reinstall main heater power connection where previously disconnected.
Rectify the cause of the fault.
IMPORTANT: Heater fault codes can be read using PC Diagnostics, however, the heater lockout reset must
be manually performed using the procedure stated above.

If you have any questions, contact our technical support team at (800) 860-7866 or via email at:
[email protected].

ATTENTION
– The engine coolant must be below 86 °F (30 °C) before the Webasto heater will attempt to start.

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Electrical Harness Schematic - Part 1, Heater Control

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Electrical Harness Schematic - Part 2, HVAC Blower Control

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Heater Plumbing Schematic - Inline Method

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Programming the 24-Hour Digital Timer
Programming the 24 Hour Digital Timer with 3 Time Settings

Time / Remaining Time Ventilation Mode Indicator

* ventilation mode not
Heater Operation Indicator available on BlueHeat

Reverse Forward
(viewing (viewing
the time) the time)

Symbol for
Setting / Viewing Program
the Time Selection

Manual Operation Program Number Indicator

Operation.
Operation of the timer is designed so that the symbols flash rapidly in the setting mode. If no
button is pressed within 5 seconds, the displayed time will be saved.
The display changes at high speed when the and buttons are pressed for more than 2
seconds.
Whenever the power supply to the timer is disconnected, all previously programmed settings
will be lost.

Switching On.
Manually: by pressing the “Manual Operation” button (continuous heating mode).
The heating time and the symbol for heating operation are displayed.
The heating time display disappears after 10 seconds.

Automatically: upon reaching the preset starting time for heating.

The program number and the symbol for heating are displayed.

Switching Off.
Manually: by pressing the “Manual Operation” button.

Automatically: via the programmed end time.

The display field goes out when the heating time expires.

Setting the Time.

This function is not available when heating mode is active!
Press and hold the button. Press the “Forward” or “Reverse” button as well.
The time of the day is displayed and the clock symbol flashes.
Set the time via the “Forward” or “Reverse” buttons.
The set time is saved when the display goes out or by pressing the button.

Viewing the Time.

Press the “Forward” or “Reverse” button.
NOTE:
The remaining operating time is displayed if heating mode is active.
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Programming the 24 Hour Digital Timer with 3 Time Settings

Continued:

Program Start of Heating.

Press the button. Press the “Forward” or “Reverse” buttons within 10 seconds until
the required time for starting heating operation is displayed.
If a different program number is required, the button must be pressed within 10 seconds.
Default start settings:
Time 1: 06:00 hours or 6:00 am
Time 2: 16:00 hours or 4:00 pm
Time 3: 22:00 hours or 10:00 pm
NOTE:
The default settings are overwritten when new values are entered. The preset times are
saved until changed. The default settings are restored when the timer is disconnected from
the on-board power supply.

Deactivate Preset Time.

Briefly press the button.

Select Preset Time.

Press the button within 10 seconds until the program number with the required preset time
is displayed. The active mode (heating ) and the program number flash.

Set Heating Duration Time.

Press and hold the button. Press the “Forward” or “Reverse” button as well.
Release both buttons. The time and clock symbol are displayed.
Press and hold the button again. Press the “Forward” or “Reverse” button as well.
Release both buttons. The preset time is displayed and the heating symbol and ventilation
symbol flash. Set the heating time via the “Forward” or “Reverse” buttons. The set
heating time is saved when the display goes out or by pressing the button.
NOTE:
The default settings are restored when the timer is disconnected from the on-board power
supply. In this case, the timer will revert to the default heating duration time setting of 30
minutes.

Set Remaining Time.

The active remaining time can be changed between 10 minutes and 60 minutes via the
“Forward” or “Reverse” buttons when heating mode is active.

* Changing the Operating Mode.

NOTE:
Ventilation mode is not available on the BlueHeat heater. The ventilation mode is only
available with certain heater versions. This information is provided in the event mode of
operation is inadvertently changed.

Press the button. Press the button again and hold it.
The last mode (heating or ventilation ) is displayed. Press the “Forward” or “Reverse”
button as well to change back and forth between heating or ventilation mode.

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Documentation Feedback Form

Detailed user feedback is extremely valuable to us in producing accurate, comprehensive, and useful
documentation.
Please complete the relevant parts of the form below; your comments and suggestions will help us improve our
documentation. Thank you.

Unsatisfactory Excellent

Please rate the overall usefulness of the documentation. 1 2 3 4 5

Rate the completeness and clarity of the instructions:

did the procedures provide enough detail? 1 2 3 4 5

What could be added or clarified?

Please list any other comments, concerns, or suggestions.

Please provided contact information below.

Name:

Company Name:

City / State:

Phone:
Mail To:
Email: Webasto Thermo & Comfort N.A., Inc.
Attn: Technical Services
15083 North Road
Fenton, MI 48430
Phone: (800) 860-7866
Fax: (810) 593-6001

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 Webasto Thermo & Comfort N.A., Inc.
Technical Assistance Hotline
USA: (800) 860-7866
Outside USA: (810) 593-6000

www.webasto.us
Org. 08/2005 Rev. 02/2018 P/N 5000778C www.techwebasto.com

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