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Webasto BlueHeat Thermo Top User Manual

Webasto BlueHeat Thermo Top
32 pages
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DOC P/N 5001274A KIT P/N 5001273A Printed in USA Webasto Product N.A., Inc.
BlueHeat Coolant Heater
Thermo Top
Legend
1 Fuse Holder, Relays and Resistor Assembly
2Timer Control
3BlueHeat Coolant Heater, Exhaust Tube, and Combustion Air Intake Silencer
4Fuel Pump
Special Tools
– Hose Clamping pliers
– Torque Wrench
Table of Contents
1
2
4
3
GMC Sierra 2500 HD
GMC Sierra 3500 HD
6.6 Liter Duramax Diesel
Beginning Model Year: 2000
Chevrolet Silverado 2500 HD
Chevrolet Silverado 3500 HD
6.6 Liter Duramax Diesel
Beginning Model Year: 2000
Special instructions for these models
Part locations may differ slightly dependent on
the vehicle model.
Foreword
Parts List 3
Vehicle Information 3
Scope and Purpose 3
Symbol Identification 4
General References 5
Preparation 5
Heater Installation Site 5
Installation
Electrical - Overview 6
Electrical Harness 7
Timer Installation 7
Fuse Tap Connection - Relay K-1 8
Integration into the Blower System 8
3-Relay HVAC Harness Connections 9
Heater Preparation 11
Heater Installation Site Preparation 12
Heater Installation (Underbody Mount) 13
Exhaust Installation 13
Combustion Air Intake Installation 13
Integration into the Coolant System 14
Integration into the Fuel System 16
Fuel Pump Installation 16
Fuel Line Routing 16
Standpipe Installation - 2000 Through 2003 18
Standpipe Installation - 2004/2006 Model Year 20
Fuel Line Routing from Sender to Pump 22
Power Connection 23
Final Inspection, Initial Start-up and Concluding
Work 24
Heater Lockout Reset Procedure 25
Electrical Harness Schematic - Part 1 26
Electrical Harness Schematic - Part 2 27
Heater Plumbing Schematic - Inline Method 28
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Webasto BlueHeat Thermo Top Specifications

General IconGeneral
BrandWebasto
ModelBlueHeat Thermo Top
CategoryAutomobile Accessories
LanguageEnglish

Summary

Safety Warnings and Prerequisites

Critical Safety Warnings

Highlights risks of fire, CO, and need for trained personnel and proper tools.

Liability and Warranty Disclaimer

States Webasto's disclaimer for improper installation and voided warranties.

Document and Vehicle Introduction

Foreword and Scope

Introduction to the manual and its intended purpose and audience.

Symbol Identification

Explains symbols used for manual sections and general cautionary notices.

General Installation Preparation

General Installation References

Guidelines for body treatment, securing components, and edge protection.

Vehicle and Kit Preparation

Covers kit verification, fuel level, battery disconnection, and component removal.

Heater Installation Site

Specifies the location for mounting the Webasto auxiliary heater.

Electrical System Installation

Electrical Overview and Components

General overview of electrical connections, timer, fuse block, and fuel pump.

Electrical Harness Routing

Guidance on routing the electrical harness and mounting bracket assembly.

Fuse Tap and Blower Integration

Connecting the fuse tap and integrating into the HVAC blower system.

HVAC Harness Connections

Specific instructions for connecting the 3-relay HVAC harness.

Heater Physical Installation

Heater Preparation and Mounting

Steps for preparing the heater and mounting bracket for installation.

Heater Installation Site Preparation

Preparing the vehicle frame for heater mounting.

Heater and Exhaust Installation

Mounting the heater and installing the exhaust tube.

Combustion Air Intake Installation

Attaching and routing the combustion air intake tube.

Fluid System Integration

Coolant System Integration

Details on integrating the heater into the vehicle's coolant circuit.

Coolant Hose Routing

Routing heater coolant hoses to the vehicle bulkhead and heater core.

Fuel System Integration

Procedures for integrating the heater with the vehicle's fuel system.

Fuel Pump and Line Routing

Installing the fuel pump and routing the fuel lines from pump to heater.

Fuel Tank Standpipe Installation

Standpipe Installation (2000-2003 Models)

Procedure for installing standpipe in fuel tank for early model years.

Standpipe Installation (2004-2006 Models)

Procedure for installing standpipe in fuel tank for later model years.

Fuel Line Routing from Sender to Pump

Routing the Mecanyl fuel line from the sender to the fuel pump.

Final Connections and Checks

Power Connection

Connecting the Webasto power and ground leads to the vehicle.

Final Inspection and Concluding Work

Checks for loose fasteners, leaks, and securing all components.

Initial Start-up Procedure

Steps for starting the heater, purging air, and verifying operation.

Troubleshooting and Schematics

Heater Lockout Reset Procedure

Steps to reset the heater's lockout mode after failed start attempts.

Electrical Harness Schematic Part 1

Diagram of the heater control electrical harness schematic.

Electrical Harness Schematic Part 2

Diagram of the HVAC blower control electrical harness schematic.

Heater Plumbing Schematic

Diagram showing the inline coolant plumbing schematic.

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