Webasto BlueHeat User Manual

DOC P/N 5001063A KIT P/N 5001062B Printed in USA Webasto Product N.A., Inc.
BlueHeat Coolant Heater
Thermo Top
Legend
1BlueHeat Coolant Heater, Exhaust Tube, and Combustion Air Intake Silencer
2 Fuse Holder, Relays and Resistor Assembly
3Timer Control
4Fuel Pump
Special Tools
– Hose Clamping pliers
– Torque Wrench
Table of Contents
4
2
3
1
VW Passat
Beginning Model Year: 2005
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 8
Integration into the Blower System 8
3-Relay HVAC Harness Connections 9
Heater Preparation/Installation 10
Integration into the Fuel System 11
Standpipe Installation 11
Fuel Pump Installation 12
Fuel Line and Electrical Harness Routing 13
Integration into the Coolant System 15
Webasto Heater Hose Integration Point 16
Webasto Heater Outlet Hose Installation 16
Webasto Heater Inlet Hose Installation 16
Heater Mounting Site 17
Fuel Line Connection at Heater 17
Air Intake Silencer Installation 17
Exhaust System Installation 18
Power and GroundConnections 18
Fuse Tap Connection - Relay K-1 18
Final Inspection, Initial Start-up and Concluding
Work 19
Heater Lockout Reset Procedure 20
Electrical Harness Schematic - Part 1 21
Electrical Harness Schematic - Part 2 22
Heater Plumbing Schematic - Inline Method 23

Webasto BlueHeat Specifications

General

Brand	Webasto
Model	BlueHeat
Category	Heater
Language	English

Summary

Symbol Identification

Symbols that define sections in manual

Identifies symbols used to denote manual sections.

General Symbol Descriptions

Explains general symbols used for warnings and attention.

General References

Preparation

Steps to prepare the vehicle and kit before installation.

Heater Installation Site

ATTENTION

Notes the location of the auxiliary coolant heater installation.

Electrical - Overview

Fuse Block/Relays/Resistor

Details the fuse block, relays, and resistor assembly location.

HVAC Blower Motor

Shows integration point for blower control and glove box area.

Digital Timer (Sample Location)

Provides a sample location for the digital timer installation.

Fuel Metering Pump

Identifies the fuel metering pump and its location.

Electrical Harness

Routing Harnesses Through Bulkhead

Guides routing of control and fuel pump harnesses through the bulkhead.

Timer Installation

Integration into the blower System

Connects the blower harness to the blower motor area.

HVAC Blower Motor Location

Specifies the location of the HVAC blower motor.

3-Relay HVAC Harness Connections

Legend for Figure 10

Explains the components and connections in the wiring diagram.

Heater Preparation/Installation

Relocating Vehicle Relay

Details relocating the vehicle relay for heater mounting.

Integration into the Fuel System

Standpipe Installation

Instructions for drilling and preparing the fuel sender for the standpipe.

Standpipe Assembly

Details on assembling and preparing the standpipe for installation.

Standpipe Installed

Fuel Pump Installation

Guides mounting the fuel pump to the vehicle.

Connecting Fuel Line to Fuel Pump

Fuel Line and Electrical Harness Routing

Routes fuel lines and electrical harness from the fuel pump.

Integration into the Coolant System

Coolant flow and connection detail

Illustrates coolant flow and connection points for the heater.

Hose Connections at Heat Exchanger

Webasto Coolant Hose Integration Point

Specifies the point for integrating the Webasto coolant hose.

Webasto Heater Outlet Hose Installation

Details connecting the heater outlet hose to the heater core.

Webasto Heater Inlet Hose Installation

Details connecting the vehicle heater hose to the heater inlet.

Heater Mounting Site

Connecting Mecanyl Fuel Line to Heater

Connects the Mecanyl fuel line to the heater inlet.

Mounting the Heater

Mounts the heater to the vehicle using hardware and screws.

Air Intake Silencer Installation

Installs the air intake silencer onto the silencer tube.

Exhaust System

Power and Ground Connections

Connects power and ground leads to the battery terminals.

Fuse Tap Connection - Relay K-1

Details the fuse tap connection for relay K-1.

Final Inspection Initial Start-up and Concluding Work

Final Inspection

Checks for loose fasteners and proper routing of all components.

Initial Start-up

Procedures for topping off coolant and initial heater startup.

Concluding Work

Final checks, securing lines, and installing removed parts.

Heater Lockout Reset Procedure

ATTENTION

Provides important notes regarding coolant temperature and technical support.

Electrical Harness Schematic - Part 1, Heater Control

Legend for Figure 10

Lists components and their designations in the schematic.

Electrical Harness Schematic - Part 2, HVAC Blower Control

FUNCTION

Explains the heater's function and interaction with the vehicle blower.

Heater Plumbing Schematic - Inline Method