Thermo 50 Coolant Heater. HMMWV 6.2 and 6.5 Liter Diesel. Table of Contents. Foreword

Transcription

1 Thermo 50 Coolant Heater HMMWV 6. and 6.5 Liter Diesel Special instructions for these models Part locations may differ slightly dependent on the vehicle model. Table of Contents 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 Swingfire Heater Component Removal 7 Heater Preparation and Mounting 8 Integration into the Coolant System 9 Integration into the Fuel System Exhaust System Installation 3 Electrical Harness Connections 4 Power Connection 5 Conclusion Programming Digital Timer 6 Final Inspection, Initial Start-up and Concluding Work 7 Heater Lockout Reset Procedure 8 Thermo Top 50 Overview 9 Thermo Top 50 Fault Codes 0 Thermo Top 50 Diagnostic Flow Chart Electrical Wiring Schematic 4 Service Parts 5 DOC P/N A KIT P/N A Printed in USA Webasto Thermo & Comfort N.A., Inc.

2 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. Installation and repair of Webasto heating and cooling systems requires special Webasto training, technical information, special tools and special equipment. NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills, technical information, tools and equipment required to properly complete the necessary procedures. 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.

3 HMMWV Coolant Heater Parts List Quantity Part Part Number Heater Kit (with installation hardware) A Vehicle Information Manufacturer Model Year Engine Type AM General HMMWV N/A 6. Liter 6.5 Liter Foreword This installation requires special expertise from a Webasto training course to install a Webasto Thermo 50, which means that it may only be installed by specially trained personnel. Webasto cannot accept any liability for faults and damage caused by the system being installed by untrained personnel. Scope and Purpose These non-binding installation instructions are intended to support authorized Webasto trained personnel in the installation of the Thermo 50 Coolant Heaters. These non-binding installation instructions apply to the vehicles listed on the front cover of this installation document unless technical modifications on the vehicle influence the installation, excluding all liability claims. Depending on the version and equipment in the vehicle, changes may be required to the installation work set out in these installation instructions. In any event, however, the directives in the installation manual and operating manual Thermo 50 must be followed. Acknowledged engineering conventions must be observed for the installation work. 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. 3

4 Coolant Heater HMMWV Symbol Identification 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 4

5 HMMWV Coolant Heater 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. Preparation Heater Kit Verify and identify all contents of kit. Vehicle Disconnect negative terminal of vehicle battery(s). Drain engine coolant into a suitable container. Remove engine access cover (doghouse). Heater Installation Site The Webasto Auxiliary Coolant Heater is to be installed under the hood and behind the washer bottle. () Webasto Auxiliary Coolant Heater (Installed) Fig. 5

6 Coolant Heater HMMWV Electrical - Overview The routing of cables and wires are done in accordance to the general valid rules of engineering. If not described differently, securing of wiring and cables is done with cable ties to the vehicle s own wires and cable harnesses. Power and Ground Connections Fuel Metering Pump Heater Connection Digital Timer 6

7 HMMWV Coolant Heater Swingfire Heater Component Removal If vehicle is equipped with a Swingfire heater, disconnect and remove the Swingfire tube, hoses and water pump. Refer to the appropriate Service Manual for removal instructions. Proceed to the Webasto Heater Preparation and Mounting section of this manual if the vehicle is not equipped with the Swingfire heater. () Swingfire Heater Tube Fig. () Swingfire Heater Coolant Connections Fig. 3 3 (3) Swingfire Heater Water Pump Fig. 4 4 Connect the engine coolant outlet hose to the heater core inlet hose. (4) Engine Coolant Outlet Hose Fig. 5 7

8 Coolant Heater HMMWV Heater Preparation and Mounting Install heater mounting bracket on heater with three self tapping screws supplied. () Heater Mounting Bracket () Self Tapping Screws (3) Webasto Heater 3 Fig. 6 Connect heater air intake tube, and wiring harness to heater. 4 (4) Air Intake Tube (5) Heater Harness 5 Fig. 7 Connect Mecanyl fuel line to heater with fuel line coupler and two clamps. (6) Mecanyl Fuel Line (7) Fuel line clamp - Torque Nm ( lb-in.) (8) Fuel Line Coupler CAUTION Check behind bulkhead for obstructions before drilling holes. Position Webasto heater on bulkhead in location shown in Figure 9. Using the mounting bracket as a template, mark and drill four holes through vehicle cowling. Secure Webasto heater to vehicle cowling with hardware provided in kit. (3) Webasto Heater () Heater Mounting Bracket (9) Vehicle Cowling Fig Fig. 9 8

9 HMMWV Coolant Heater Integration into the Coolant System Torque hose clamps to Nm (8 - lb-in.) Avoid sharp bends and kinks when installing coolant hoses. Position hose clamps in such a way to avoid cutting or damaging adjacent components. Clamp vehicle coolant hose with hose clamping pliers prior to cutting to prevent coolant spillage. Fig. 0 9

10 Coolant Heater HMMWV Remove two flanges from back of cylinder heads. () Flange Location () Back of Cylinder Head Fig. Apply gasket sealant to new coolant fittings before installing on engine block. Install supplied coolant fittings, flanges, and gaskets with existing vehicle hardware. 3 (3) Supplied Coolant Fittings 3 Fig. 36 Tighten hose clamps to Nm (8 - lb-in.). Couple left and right cylinder heads with tee fitting and coolant hose provided. (4) Hose (5) Tee Fitting (6) Hose (3) Coolant Fittings ( ea.) (7) Hose Clamps (4 ea.) Fig. 37 Connect supplied hose to tee fitting and inlet (water pump) side of Webasto heater. (8) Coolant Hose From Tee Fitting To Heater Inlet (9) Hose Clamp (5) Tee Fitting Fig. 4 0

11 HMMWV Coolant Heater Connect inlet hose to water pump and secure with hose clamp. () Webasto Heater Inlet Hose () Heater Water Pump (3) Hose Clamp 3 Fig Connect 90 degree hose to Webasto heater outlet and tighten hose clamp. Connect 90 degree outlet hose to straight hose section with coupler and clamps provided. (4) Coolant Hose Coupler (5) Coolant Hose To Engine Water Pump (6) Heater Outlet 90 Degree Hose (7) Hose Clamp (3 ea.) Fig. 6 Connect Webasto coolant outlet hose to hose leading to lower radiator hose with adapter and two hose clamps. (8) Coolant Hose Leading to Lower Radiator Hose 8 Fig. 7

12 Coolant Heater HMMWV Integration into the Fuel System Fuel Pump Installation Install heater fuel pump on vehicle bulkhead as shown in Figure 8. () Heater Fuel Pump () P-Clamp (3) Drill hole 8.0 mm (5/6 in.) (4) Bulkhead 3 4 Fuel Line Connections Always cut Mecanyl fuel line with a sharp razor knife or razor edged cutter. DO NOT cut with side cutters, scissors or similar tools as doing so will cause a restriction inside the fuel line. Tighten fuel line clamps to.0-.4 Nm ( lbin.). Connect fuel line (cut to length) from heater to outlet side of fuel pump with fuel line connector and two clamps. (5) Fuel Line Connector (6) Fuel Line Clamp ( ea.) (7) Mecanyl Fuel Line (from heater) Fuel flow through the vehicle fuel filter is identified by the arrows marked on the filter body. Cut the rubber fuel line (3/8 I.D.) at the inlet side of the vehicle fuel filter. Install fuel tee fitting as shown in Figure 0. (8) Fuel Tee (9) Vehicle Fuel Line (0) Fuel Line Clamps (5) Fuel Line Connector (7) Mecanyl Fuel Line Fig. 8 7 Fig Fig. 0 Route fuel line from fuel tee to inlet side of heater fuel pump and cut to length. Secure fuel line with nylon wire ties. Connect Mecanyl fuel line to inlet side of heater fuel pump with fuel line connector and two clamps. 7 6 (7) Mecanyl Fuel Line (6) Fuel Line Clamps (5) Fuel Line Connector 5 Fig.

13 HMMWV Coolant Heater Exhaust Installation Remove Swingfire exhaust guard and exhaust tube, if equipped. () Exhaust Tube () Exhaust Guard Fig Ensure exhaust tube does not extend below the bottom of the exhaust guard. Cut flexible exhaust tube to length and secure to the heater with clamp provided. (3) Webasto Heater (4) Exhaust Clamp (5) Flexible Exhaust tube Fig. 3 Cover flexible exhaust tube with heat protective sleeving and secure to side of vehicle with P-clips and hardware provided. 5 Install orange rubber grommet near end of exhaust tube. Install exhaust guard. (5) Exhaust Tube Covered With Heat Protective Sleeving () Exhaust Guard Fig. 4 3

14 Coolant Heater HMMWV Electrical Harness Connections Cut fuel pump harness (blue and brown wires) to length. Crimp terminals on to wires and insert terminals into plug housing. Attach plug housing to fuel pump. () Fuel Pump Electrical Harness Fig. 5 CAUTION Check behind cowling for obstructions before drilling hole. Route heater control harness through cowling, using grommet provided, into vehicle interior. Apply sealant to grommet. Image Not Available Timer Installation CAUTION Check behind panels for obstructions before drilling holes. Ensure there is adequate clearance for hand brake and throttle lock operation before installing timer mounting bracket on vehicle interior. Install timer mounting bracket with hardware provided. Snap timer into mounting bracket. () Throttle Lock (3) Timer Mounting Bracket (4) Digital Timer (5) Vehicle Handbrake Fig. 6 Fig. 7 4

15 HMMWV Coolant Heater CAUTION Ensure heater control harness is clear of moving parts (e.g. steering mechanism). Route heater control harness to timer harness area and cut to length. Connect heater control harness to timer harness using the supplied terminals and Table. Table. Timer Harness Connections Heater Control Harness Timer Harness Function Red Red + 4 Volts Green Gray On Indicator / Diagnostic Code Brown Brown Ground Black Black Timer Output / ON - OFF Signal Yellow Not Used Purple Not Used Power Connection Connect the red power wire from heater control harness to battery positive cable (+ 4 volts) at alternator. () Battery Positive Cable () Heater Control Power Wire IMPORTANT: All power connections must be fused within 4 of the battery. Fig. 8 Ground Connection 3 4 Connect the brown ground wire from heater control harness to alternator ground location. (3) Heater Control Harness Ground (4) Alternator Ground Location Fig. 9 5

16 Coolant Heater HMMWV Programming Timer To begin timer programming. Press The timer memory location number starts Concluding Day Work of On/Off flashing. Continue to press button until Check that the all week Operation hose lines, hose clamps, pipe clips and electrical connections the desired are memory secure. location Secure, all loose or 3 is lines visible. Time of Day Indicator and and Timer cables with nylon cable ties. Display To adjust start time setting. Spray the heater components and electrical connections with Press an anti-corrosive Or wax Once coating. start time is set, release Alarm Install all vehicle parts, panels and components removed during heater button. installation. Flashing will stop after 5 seconds Timer and day of the week will begin flashing. Memory Location Clock To select day of the week. Press Or Button Heater will start on the time Program Heater Day/Time Day/Time and day selected. Once set, wait for flashing to stop. Selection On/Off Reverse Advance Button Button Button Button To program the other memory locations, repeat the above 3 steps for each memory location. Setting the Time and Day of the Week: Press and hold for seconds. Time of day will start flashing. Recalling or cancelling a programmed start time: Press Or To adjust time setting. Once time is set, release button. Flashing will stop after 5 seconds and day of the week will begin flashing. To select day of the week. Or Once set, wait for flashing to stop. Operating Heater in Manual Mode: Press Press To turn the heater on. The operation indicator will light up. To turn the heater off. The operation indicator light will go out. Programming Heater Starting Time: To cycle through memory locations. Any one of the 3 memory locations can be activated each time the button is pressed. After selecting the memory location you desire, you will be able to change the day and time setting if desired by repeating steps, and 3 above. Press Press repeatedly until no memory location number is visible on timer display. Webasto Thermo & Comfort N. A., Inc North Road Fenton MI, Technical Assistance: (USA) (CAN) 6

17 HMMWV Coolant Heater Final Inspection Initial Start-up and Concluding Work Connect battery ground terminal Final Inspection Inspect installation for: Loose fasteners. Exhaust system routing and clamp tightness. Combustion air intake tube routing and clamp tightness. Loose coolant line clamps. Pinched coolant lines. Routing of coolant lines and coolant lines securely tied and protected against chafing and related damage. Loose fuel line clamps. Routing of fuel lines and fuel lines securely tied and protected against chafing and related damage. Loose wiring connections and battery connections. routing of wiring harness and wiring harness securely tied and protected against chafing and related damage. Check operation of vehicle heater fan with Webasto heater OFF. Initial Start-up Top off cooling system with coolant per engine/vehicle manufacturers recommendations. Set interior heater control to maximum heat position (hot). 3 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) 4 Switch off the engine. 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. 5 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. 6 Allow heater to run for 0 minutes or until coolant is heated to temperature. Re-tighten all hose clamps. 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. 7

18 Coolant Heater HMMWV Heater Lockout Reset Procedure The heater is designed with a lockout safety feature built into the control unit. After 3 consecutive unsuccessful startup attempts, the heater will lock itself out from any further start attempts. The heater may also enter the lockout mode after experiencing an overheat condition. Reset Heater Lockout mode by performing the following procedure: Ensure timer or switch is in the OFF position. Turn timer or switch to the On position. Remove main fuse F (5 Amp), reinsert after 5 seconds. Cycle timer or switch off and then back on once more. Remove fuse F once again and reinsert after 5 seconds. Heater should attempt to start after inserting fuse. The engine coolant must be below 86 F (30 C) before the Webasto heater will attempt to start. Should the heater fail to start or operate correctly, contact your Webasto technical representative at:

19 HMMWV Coolant Heater Thermo Top 50 - Overview CAUTION Troubleshooting requires comprehensive knowledge about the structure and theory of operation of the Thermo Top heater. Troubleshooting and repairs may only be performed by Webasto trained and certified, professionals. Functional Description - Thermo Top Switch On Push the timer ON/OFF button to illuminate the indicator lamp; activate the heater glow pin, combustion air fan and the circulation pump. After 30 seconds the fuel pump starts and the combustion air fan operation is suspended for 3 seconds. Subsequently, the combustion air fan speed is increased in two ramps within 56 seconds to part load operation. After a stabilization phase (constant speed) of 5 seconds the combustion air fan speed is again increased in a ramp within 50 seconds to full load. After reaching full load, the glow pin is deactivated and the combustion air fan operation is increased. During the next 45 seconds and during normal heater operation, the glow pin functions as a flame sensor to monitor the flame condition. Once the start-up and stabilization periods have been completed the heater begins the automatically controlled heating operation. In case of a no-flame condition during start-up or a flameout during normal combustion operation, the heater will go into a shut-down upon malfunction state with a run-down of the combustion air fan. Heating Operation When the coolant reaches temperature the heater switches to the energy saving part load operation. A rise in coolant temperature above the upper threshold causes the heater to enter a control idle period. The circulation pump and the operation indicator light remain on during control idle. After cool-down of the coolant, the heater resumes full load operation. Another rise in coolant temperature above the upper threshold causes the heater to enter the control idle period again. A drop in the coolant temperature during part load operation due to an increased demand in heat will cause the heater to switch to full load operation. Switch Off Pushing the timer ON/OFF button extinguishes the indicator lamp, combustion terminates and the shutdown phase commences. The circulation pump and the combustion air fan continue operation during the shutdown phase to cool the heater down and will be automatically switched off afterwards. The duration time and the combustion air fan speed during the shutdown phase depend on the heater operating condition at the time the heater is turned off. Shut-down time duration is normally 80 seconds (3 minutes) when deactivated in full load operation and 00 seconds (.6 minutes) when deactivated in part load operation. Dependent on the software variant implemented in the control unit there might be time duration deviations from those shut-down periods as stated. 9

20 Coolant Heater HMMWV Thermo 50 - Fault Codes The Thermo top 50 is equipped with an electronic control module which is capable of providing the following diagnostic fault codes. If a malfunction is detected by the control module during heater operation a fault code will appear on the digital timer display. Fault Code Description Possible cause F0 No Start-up Fuel Supply Restricted Air Flow Through Intake or Exhaust F0 Flame Extinguished Fuel Supply Restricted Air Flow Through Intake or Exhaust F03 Under / Over Voltage Vehicle Charging System F04 Premature Flame Detection Replace Heater F05 Circulating Pump Interruption or Short Circuit Open or Shorted Wiring Defective Pump F06 Temperature Sensor Interruption or Short Replace Heater Circuit F07 Metering Pump (fuel pump) Interruption Open or Shorted Wiring or Short Circuit F08 Combustion Fan Motor Interruption, Short Replace Heater Circuit or Incorrect Fan Speed F09 Pencil Type Glow Plug / Flame Detector Replace Heater Interruption or Short Circuit F0 Overheating Condition Coolant Flow Restriction Circulation Pump This manual is intended for installation and basic troubleshooting of the Thermo 50 coolant heater. Refer to for detailed repair and maintenance procedures. 0

21 HMMWV Coolant Heater Thermo Top 50 - Diagnostic Flow Chart Troubleshooting is normally limited to the isolation of defective components, wiring and connections. The following possible causes for trouble have not been taken into consideration and must always be excluded as a possible cause for malfunctions: power supply to heater is less than volts at main power connections (charge batteries and perform load test). See wiring diagram on page 4 for reference to power connections. blown fuses. corrosion on battery terminals for heater, electrical wiring, connections and fuses. loose contacts or connectors, wrong crimping on connectors. ensure heater and components have been correctly installed following all pertaining installation instructions. Troubleshooting Steps After 3 consecutive unsuccessful startup attempts, the heater will lock itself out from any further start attempts. The heater may also enter the lockout mode after experiencing an overheat condition. Before troubleshooting the heater, ensure heater is not in the Lockout mode by performing the following reset procedure:. Ensure switch is in the off position. Turn switch to the on position. Remove fuse F (5 Amp), refer to wiring diagram on page 4 for identification. Reinsert after 5 seconds.. Cycle switch off and then back on once more. Remove fuse F once again and reinsert after 5 seconds. Heater should attempt to start in 0 seconds after inserting fuse. Coolant temperature must be belowthe lower threshold before heater will attempt to start. NO Did heater attempt to start? (Combustion fan running) Check for 4V on signal at heater connector X, pin 3 with timer/switch on. Repair or replace harness, connectors, fuses, or timer/switch accordingly. Check for 4V at heater connector X, pin. Repair or replace harness, connectors, connections or fuses accordingly. Check for ground at heater connector X, pin Repair or replace harness, connectors or connections accordingly. YES Continued on page Replace Thermo Top

22 Coolant Heater HMMWV Thermo Top 50 - Diagnostic Flow Chart NO Is combustion air intake free from damage and obstructions? Repair/replace air intake tube or remove obstruction accordingly. Is combustion exhaust pipe free from damage and obstructions? Repair/replace exhaust pipe or remove obstruction accordingly. YES Does fuel pump operate (clicking) during start-up cycle approx. 30 sec. after switching on? Connect test light to fuel pump leads (leads connected normally). Does the light blink slowly after 30 sec. of switching the heater on? Is fuel pump harness free of damage? Replace heater. Repair or replace harness accordingly. Reconnect fuel pump and turn heater on. After 30 sec. lightly tap fuel pump. Does fuel pump begin to operate (Click). Replace fuel pump. System should resume normal operation. Pump may have been stuck due to dirt in fuel or long periods of no operation. Perform visual check of fuel pump. Is fuel moving through the fuel line with each pulse of the fuel pump? Are fuel lines free of obstructions? Are fuel lines free of damage, pinched sections, or leaks? Are the fuel line clamps tight? Is there sufficient fuel in the fuel tank? Repair/replace damaged or obstructed fuel lines. Tighten loose fuel line clamps. Fill fuel tank with sufficient fuel to reach fuel standpipe inlet. Continued on page 3 Replace fuel pump.

23 HMMWV Coolant Heater Thermo Top 50 - Diagnostic Flow Chart CAUTION Allow heater to cool down before disassembly of coolant circulating pump. Allow heater to cool down before attempting to restart. NO Does coolant pump operate when heater is running (can feel or hear pump running)? Remove center plastic cover from heater. Disconnect coolant pump connector X5. Apply 4V directly to the pump (+ to black and to brown). Does pump operate? Remove coolant pump and 4 cover screws. Clean pump accordingly. Assemble and reconnect pump. Does pump now operate? Replace coolant circulating pump. YES Replace heater. Problem resolved. Test run heater. Does heater start and operate normally? Check coolant hoses for obstructions, kinked hoses, low coolant level and proper hose routing, etc. Heater is operating normally. Possible intermittent problem. Should problem reoccur, rerun through this troubleshooting tree. 3

24 Coolant Heater HMMWV WEBASTO THERMO 50 - HMMWV SCHEMATIC WITH DIGITAL TIMER B TEMPERATURE SENSOR E CERAMIC IGNITER/FLAME SENSOR F 5A FUSE F 5A FUSE M COMBUSTION AIR FAN M COOLANT CIRCULATION PUMP S ON/OFF SWITCH-TOGGLE X CONNECTOR 6-WAY X CONNECTOR -WAY X3 CONNECTOR -WAY X4 CONNECTOR -WAY X5 CONNECTOR -WAY X7 CONNECTOR -WAY X8 CONNECTOR -WAY X9 FUSE HOLDER Y FUEL PUMP X9 F F RED 4GA BLACK 8GA ON SIGNAL TO HEATER X5 X4 X3 CONTROL 8 BATTERY - X X X3 X4 X BLUE 8GA RED GA + B E X8 D C A F RED 4GA GREEN 8GA X X7 A X M M B Y E M M B BROWN 8GA HEATER DWG NO: 90868A RELEASED 5/7/03 G. MILLER - BRN YELLOW 8GA COMPUTER DIAGNOSTICS DOWNLOAD LINK INDICATOR/DIAGNOSTIC LIGHT + FUEL PUMP + BATTERY + FUSED POWER BROWN 8GA BROWN 4GA BROWN GA GRY BLK RD Digital Timer MATING END SHOWN X 3 X X3, X4 and X5 X7 INTERNAL TO HEATER X8 X9 A B C D E F A B

25 HMMWV Coolant Heater Service Parts Item Quantity Part No. Description Remarks Formed Heater Hose 3MT Heater Hose 5/8 I.D Gasket Elbow Fitting 3/4 MNPT x 3/4 BARB 90 Degree Tee Hose Coupler Hose Coupler Hose Clamp Flange Adapter 5

26 Coolant Heater HMMWV Service Parts Item Quantity Part No. Description Remarks Exhaust Tube Heat Protective Sleeving Screw M6x Washer M Locknut Exhaust Grommet Exhaust Clamp Exhaust P-Clamp 6

27 HMMWV Coolant Heater Service Parts Item Quantity Part No. Description Remarks Heater Control Harness 8500 FP Harness Connector Housing FP Harness Weather Seals Terminal End Grommet Electrical Connector Ring Terminal 3/ Ring Terminal / Timer Mounting Bracket Mounting hardware included Digital Timer Harness included 7

28 Coolant Heater HMMWV Service Parts Item Quantity Part No. Description Remarks 8978 Fuel Line Tee Worm Clamp 3 4MT Black Fuel Line Air Intake Tube Nylon Cable Tie Fuel Line Connector Hose Clamp 8

29 HMMWV Coolant Heater Service Parts 4 3 Item Quantity Part No. Description Remarks Thermo 50 Coolant Heater KIT - Includes items Heater Mounting Bracket P-Clip Used to mount fuel pump Fuel Pump 9

30 Coolant Heater HMMWV Service Parts Item Quantity Part No. Description Remarks 9834 Burner (Diesel) With screws and gaskets 9835 Combustion Air Fan Burner Head + Heat Exchanger + Control Unit - 4 V With screws, gaskets and sealants Screw - EJOT PT 0 DG 60x8 For fastening bracket to heater Pump Housing (93 Degree) Pump Housing (Axial) Circulation Pump - 4V U4847 With seals and screws 30

31 HMMWV Coolant Heater NOTES: 3

32 Webasto Thermo & Comfort N.A., Inc. Technical Assistance Hotline USA: (800) Canada: (800) Org. 8/004 Rev. /05 P/N A