BlueHeat Coolant Heater

BlueHeat Coolant Heater Dodge Ram 500 / 3500 003 / 004-5. Liter Gasoline 003 / 006-5.9 Liter Diesel 00 6. Liter Diesel Installation Instructions DOC P/N 500068B KIT P/N 5000498C

PRELIMINARY INFORMATION BLUEHEAT - DODGE RAM 500 / 3500 Table of Contents Foreword Page Scope and Purpose......................... Tools Required............................ Heater Installation Site...................... 3 Vehicle Preparations........................ 3 Installation Electrical Harness.......................... 4 Blower Connection......................... 6 Timer Installation.......................... 8 Integration into Fuel System.................. 8 Heater Installation......................... Integration into Coolant System...............4 Exhaust System...........................6 Power Connection.........................6 Concluding Work..........................6 Final Inspection and Initial Start-up............. Basic Troubleshooting.......................8 Wiring Schematics.........................0 Coolant Schematic......................... Foreword Scope and Purpose These non-binding installation instructions are intended to support authorized Webasto trained distributors, dealers and personnel in the installation of the Thermo Top BlueHeat 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 Top must be followed. The appropriate 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. Tools Required /4 Drive Ratchet /4 Drive 4 inch extension 0 mm six point socket, /4 drive 0 mm six point deep well socket, /4 drive 3/8 Drive Ratchet 3/8 Drive inch extension 3 mm socket, 3/8 drive 5 mm socket, 3/8 drive mm socket, 3/8 drive 0 mm combination wrench 8 mm nut driver Phillips # screwdriver Combination side-cut/crimping pliers Hose clamping pliers Hose cutting pliers Drill.5 mm (3/3 in.) drill bit 8 mm (5/6 in.) drill bit 0 mm (5/64 in.) drill bit Hacksaw Utility Knife Mechanic s wire - feet Hoisting equipment and safety stands Vehicle manufacturer s service reference manual

BLUEHEAT - DODGE RAM 500 / 3500 PRELIMINARY INFORMATION Heater Installation Site The Webasto auxiliary coolant heater is to be installed on the right frame rail near the front bumper. Refer to Figures and for location of heater.. Front Fig. Fig. Vehicle Preparations Heater Kit. Verify and identify all contents of kit. Vehicle. Verify fuel content in tank. CAUTION For safety reasons due to weight of fuel and tank, it is recommended there be no more than ¼ tank or less of fuel present. If fuel quantity is greater than ¼ of capacity, make provisions to reduce quantity of fuel or consider removal of pick-up box to gain access to fuel sender location if feasible.. Disconnect negative terminal of vehicle battery(s). 3. Remove lower instrument panel fascia (above steering column) to gain access to timer and blower motor harness. Refer to vehicle manufacturer s instructions for removal. 4. Remove the ash tray and center console fascia. Refer to vehicle manufacturers instructions for removal. 5. Remove right front fender splash shield. 6. Protect vehicle fenders with fender covers and protect seating surfaces against soiling. 3

INSTALLATION BLUEHEAT - DODGE RAM 500 / 3500 Universal Electrical Harness - Description 3 Legend for Figure 3 6 - Fuse Holder and Fuses 5 4 - Resistor - HVAC blower speed control 3- Relay K - HVAC control 4 5 4- Relay K - HVAC control 6 5-8 GA Green - ON signal from relay K and K to relay K3, Pin 86 (Use when relay K3 is mounted with relay K and K) 6-8 GA Blue - to Ignition ON signal source - Main Heater Harness - BlueHeat Coolant Heater 8- Blower Control Harness - Positive side 3 0 9-0 GA Red - Connects to HVAC control switch circuit, positive side, to blower motor 0-0 GA Black - Connects to HVAC blower motor positive side - 8 GA Green - ON signal from relay K and K to 9 relay K3, pin 86 (Use when relay K3 is mounted 8 near HVAC blower motor - same function as item 5) 9 - Blower Control Harness - Negative side (Harness is wire tied to main harness. Cut wire tie 8 and separate from main harness before installing) 0 3-0 GA Blue - Connects to HVAC control switch circuit, negative side, to blower motor 4-0 GA White - Connects to HVAC blower motor negative side 5-0 GA Brown - Connects to vehicle ground point when relay K3 is mounted near HVAC blower motor 6 6-8 GA Green - Relay K3, pin 86 (Connects to ON 3 signal 8 GA green from relay K and K). See item 5 and. 4 5 - Relay K3 - HVAC control (Typically mounted near HVAC blower motor) 8-8 GA Blue & Brown - Fuel Metering Pump Harness Fig. 3 9-0 GA Black, Red & Brown - Timer Harness 0-8 GA Violet - Vent Mode for optional remote control - Main Power Harness - 0 GA Red - Battery Positive 3-0 GA Brown - Battery Negative or Ground Point 4-8 GA Yellow - Diagnostic Connection 5-8 GA Orange - Supplemental heating option - Not applicable to BlueHeat 6-0 GA Brown - Optional ground connection for relay K3 when K3 is mounted with relay K and K (Same function as item 5) 4

BLUEHEAT - DODGE RAM 500 / 3500 INSTALLATION Installation Drill two holes in vehicle bulkhead () for mounting the fuse, relay, resistor cluster. Refer to Figure 4. Fig. 4 Install two relays (3) and resistor () on mounting bracket (4) with hardware provided. Refer to Figure 5. Install mounting bracket (4) on bulkhead () with two M6 capscrews and nuts. In this application the fuses were mounted behind the mounting bracket (4) using a nylon wire tie. 4 3 Harness Routing Fig. 5 Route heater control harness (5) to the passenger side of the engine compartment following the vehicle battery cables (6). Route heater control harness (5) down to the heater mounting location along the fan shroud (). Refer to Figure 6. Use the existing harness clips and nylon cable ties to secure heater control harness. 5 6 Fig. 6 NOTE: The timer and blower control harnesses can be routed through unused bulkhead grommets if available, otherwise perform the following step. Cut a ½ inch hole in the bulkhead main harness grommet (8). Route timer and blower control harnesses (9) through grommet (8) into the drivers foot-well area. Refer to Figure. 8 9 Fig. 5

INSTALLATION BLUEHEAT - DODGE RAM 500 / 3500 Pull main blower control harness (3) and timer harness () through grommet () in footwell area. Refer to Figure 8. Route main blower control harness (3) under dash to the blower motor (4). The blower motor (4) is located below the glove box on the passenger side of the vehicle. Refer to to Figure 9. Fig. 8 3 Integration into the Blower System NOTE: It is permissible to cut excess length from blower control wiring harnesses. Mount blower control K3 relay (6) with auxiliary blower control harness (5) to vehicle near blower motor (4). Refer to Figure 9. 6 5 4 Cut auxiliary blower control harness (5) to desired length. Fig. 9 Crimp connect green wire (9) from main blower harness (3) to green wire pigtail (8) at auxiliary blower control harness (5). Refer to Figure 0. Connect brown (ground) wire () from auxiliary blower control harness (5) to a suitable ground point on the vehicle. 5 3 9 Fig. 0 8 Identify the positive and negative blower control wires (0) connected to the vehicles blower motor (4). Refer to Figure. Cut both vehicle blower control wires at a point about 50 mm ( in.) from motor plug and make the connections as described in the following steps. Also, see Figure 4 4 0 Fig. 6

BLUEHEAT - DODGE RAM 500 / 3500 INSTALLATION Ensure that connections are done correctly. For more detail of wiring circuits, turn to the back of this manual for complete wiring schematics. Positive blower wire. Connect the red wire (3) to the vehicle side of the positive wire (4). Refer to Figure.. Connect the black wire () to the blower motor side of the positive wire (). 4 Fig. 3 Negative blower wire. Connect the blue wire () to the vehicle side of the negative blower wire (8). Refer to Figure 3.. Connect the white wire (6) to the blower motor side of the negative wire (5). 8 5 6 Fig. 3 Legend for Figure 8 A From Webasto Heater X B VDC Ignition On Fuse Tap C HVAC Control Module M HVAC Blower Motor X Cut wire at 50 mm ( in.) from motor F Fuse - Blower Circuit 5 Amp K Relay - Ignition On Interrupt K Relay - Positive Side of Blower Motor Circuit K3 Relay - Negative Side of Blower Motor Circuit R Resistor - Blower Speed Control 30 Battery Positive (Constant Power) 5 Ignition (Switched Power) 3 Battery Negative (Chassis Ground) Webasto Vehicle Fig. 4

INSTALLATION BLUEHEAT - DODGE RAM 500 / 3500 Timer Installation (General Instructions) DO NOT OVER TIGHTEN MOUNTING SCREW! NOTE: Before installing the timer, please confirm the installation site with your customer. After selecting a site for the timer, temporarily apply the timer mounting template. Refer to Figure 5 for a translated sample of the template. Before drilling into any panels, ensure there are no hidden components behind the panel that may be damaged or interfere with the timer installation! As specified on template, drill the 0 mm (5/64in.) and the.5 mm (3/3 in.) holes. Remove drilling template. Route the timer harness through the 0 mm (5/64 in.) hole. Apply foam cushion to back of timer. 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 until the timer with foam cushion is firmly seated against panel. Refer to Figure 6. Tighten screw no more than 0.8 Nm (.0 lb-in.). DO NOT OVER TIGHTEN! Refer to Figure 6 for a completed timer () installation example. Fig. 5: Timer Template (NOT TO SCALE!) Fig. 6: Timer Placement (EXAMPLE ONLY!) Integration into Fuel System CAUTION Full to partially filled fuel tanks are heavy and awkward to handle. If fuel tank removal is necessary to access fuel sender, ensure fuel level is near empty. To prevent accidents or injury to personnel, make sure tank is well supported prior to removing mounting hardware. Follow the manufacturers service procedure to access and remove the fuel sender unit from fuel tank. Ensure standpipe location does not interfere with fuel sender float movement. Recommended Standpipe Location - 5.9L Diesel (00-004) Drill a 8.5 mm (/64 in.) hole () through the fuel sender () in the location shown in Figure. To prevent fuel seepage around standpipe, remove burrs from both sides of hole () after drilling. Fig. 8

BLUEHEAT - DODGE RAM 500 / 3500 INSTALLATION Recommended Standpipe Location - 5.9L Diesel (Spacer Required) Position the fuel sending unit spacer (3) in the slot identified in figure 8. Use the spacer as a template to mark the hole location for standpipe installation. Remove spacer before drilling hole. Drill a 8 mm (5/6 in.) hole () through the fuel sender () in the location marked. To prevent fuel seepage around standpipe, remove burrs from both sides of hole () after drilling. Reinstall spacer (3) into slot in fuel sender (), ensuring the beveled edge is facing down. Recommended Standpipe Location - 5.L Gasoline (HEMI) Drill a 8.5 mm (/64 in.) hole through the fuel sender () in a location suitable for standpipe installation. See Figure 9. To prevent fuel seepage around standpipe (4), remove burrs from both sides of hole after drilling. Fig. 8 3 Fig. 9 4 Installing Standpipe with 90 Degree Banjo Fitting 5 6 NOTE: Cut standpipe to a length approximately 5 mm ( in.) from the bottom of the fuel tank with a 45 slash-cut. Remove any burrs after cutting tube. Do not cut standpipe used for the HEMI application at this time. Preview instructions on page 0 before proceeding. 4 8 Cut standpipe (4) to length (approximately 3.5 in.) and bend if necessary to clear any fuel sender components. Place one sealing washer () on standpipe (4) and insert standpipe (4) through drilled hole. See Figure 0. Place remaining sealing washer() on standpipe from underside. Secure standpipe (4) with lock nut (9). Tighten lock nut to a torque of 9 ± 0.5 Nm. (80 ± 4.4 lb-in.). If necessary, to reposition banjo fitting (6) outlet, loosen banjo bolt (5) to allow movement. Banjo outlet should run in the same direction as the other fuel outlet pipes. Tighten banjo bolt to a torque of 9 ± 0.5 Nm. (80 ± 4.4 lb-in.) after repositioning outlet. Fig. 0 Legend for Figure 0 5 Banjo Bolt 6 Banjo Fitting - 90 Degree 4 Standpipe Sealing Washer 8 Fuel Tank or Sender Plate 9 Lock Nut 9 9

INSTALLATION BLUEHEAT - DODGE RAM 500 / 3500 Fuel Standpipe Instructions - 3500 (HEMI) Bend standpipe () 90 degrees as shown in Figure. Fig. NOTE: Use the slotted tube molded into the side of the sending unit to secure the standpipe away from the fuel level float. Insert standpipe () into slotted tube (3) in fuel sender () as shown in Figure. 3 Fully extend fuel sender (). Mark standpipe () length to approximately 5 mm ( in.) from bottom of fuel sender (). Collapse fuel sender () and cut off excess standpipe () where marked. The overall length of the standpipe (), after the bend, is 34 cm (3.5 in.). Fig. 8 4 6 Connecting Fuel Line to Outlet Fitting - All Install fuel sender unit () according to the vehicle manufacturers service procedures. Align outlet fitting (4) with vehicle fuel lines, as shown in Figure 3. Install rubber fuel line connector () on fuel standpipe banjo outlet nipple and secure with clamp (8). Place clamp (6) over rubber connector and insert plastic fuel line (5) into connector until it bottoms out against nipple. Secure with clamp (6) as shown in Figure 3. Observe Figure 4 for correct fuel line connecting. Cover the fuel line (5) with conduit and snap into molded hold down on the fuel tank. Refer to Figure 3. If fuel tank was removed to gain access to sender, install tank according to manufacturers service procedures. 5 Fig. 3 Fig. 4 0

BLUEHEAT - DODGE RAM 500 / 3500 INSTALLATION Fuel Pump Installation - Diesel Install fuel pump (5) on vehicle frame with hardware provided in kit. Refer to Figure 5 for mounting location. Install rubber fuel line adapter (3) on inlet side of fuel pump (5) and secure with clamp (4). Insert fuel line () into rubber fuel line adapter (3) until it bottoms out against nipple and secure with clamp (). Fig. 5 3 4 5 Front Install rubber fuel line adapter (8) on outlet side of fuel pump (5) and secure with clamp (). Refer to Figure 6. Insert fuel line (0) into rubber fuel line adapter (8) until it bottoms out against nipple and secure with clamp (9). Route fuel pump harness (6) to fuel pump (5) following vehicle brake/fuel lines and connect to fuel pump (5) Front 6 5 8 9 0 Fig. 6 Cover the fuel line (0) with black conduit. Route the fuel line (0) with the vehicles fuel lines () to the underhood compartment. Refer to Figure. 0 Fig. Front Fuel Pump Installation - RAM 3500 (HEMI) The fuel pump () for the HEMI application is located above the fuel tank on the frame as shown in Figure 8. Follow the instructions above for fuel pump installation. Fig. 8 Front

INSTALLATION BLUEHEAT - DODGE RAM 500 / 3500 Route the fuel line () along fuel pump harness () and vehicle lines toward the engine compartment. Refer to Figure 9. Fig. 9 CAUTION Ensure fuel line is secured away from hot exhaust components. Use nylon wire ties to secure fuel line () and fuel pump harness () to frame rail. Refer to Figure 30. Fig. 30 Front Route the fuel line () along heater control harness (3), across radiator, to the heater mounting location. Refer to Figure 3. Secure fuel line () to the heater control harness (3) using nylon wire ties. 3 Heater Installation Some preassembly of the heater is necessary before installing. The next steps will detail the installation of the mounting bracket and the combustion air intake tube. Install EJOT stud () with M6 washer before installing heater mounting bracket (5) on heater. See Figures 3 and 35. Fig. 3 4 5 6 Install heater mounting bracket (5) on heater with two EJOT screws (4). Install heater support bracket (6) on EJOT stud () with nut provided. Do not tighten nut until heater is installed on frame. Fig. 3

BLUEHEAT - DODGE RAM 500 / 3500 INSTALLATION Remove knock out from top of heater (5) and install the combustion air silencer clamp (3). Refer to Figure 33. Install combustion air intake tube () on heater and secure with clamp (). Thread combustion air silencer (4) into combustion air tube (). Secure combustion air silencer (4) to top of heater (5) with previously installed clamp (3). 3 Fig. 33 5 4 Remove right front wheel well splash shield to gain access to installation site (). Prepare installation site () by cutting away the lower section of the right front spalsh shield (6) (if equipped). See Figure 34. 6 Fig. 34 Refer to Figure 35 for an overview of how the Webasto heater is installed. Fig. 35 Install the heater mounting bracket (8) on vehicle frame rail (9) with two bolts (), spacers (), rear strap, and two nuts (0). Refer to Figures 35 and 36. 8 Fig. 36 0 9 3

INSTALLATION BLUEHEAT - DODGE RAM 500 / 3500 Secure heater support bracket (3) to the frame / bumper mounting bolt with nut () provided. Refer to Figure 3. Tighten nut securing heater support bracket (3) to EJOT stud(). 3 Fig. 3 Fuel and Electrical Connections at Heater 4 Connect heater control harness (4) to the heater. Refer to Figure 38. Pre-assemble rubber fuel line adapter (6) with two clamps. Install rubber fuel line adapter (6) on heater and secure with clamp (). Insert fuel line (8) into rubber adapter (6) until it bottoms out against the fuel inlet nipple and tighten clamp (5). 5 6 Fig. 38 8 Integration into Coolant System - Diesel 9 0 Cut the two formed coolant hoses found in kit to.54m (5 foot) sections. Cut the 80 degree end to 90 degrees on both hoses. Cover both hoses with black conduit before installing. Connect 90 degree end of heater inlet hose () and heater outlet hose (9) to heater and tighten hose clamps (0). See Figure 39. 0 Fig. 39 CAUTION! Ensure coolant lines are secured away from all suspension parts and heat sources! 9 Route heater coolant hoses (9) and () as shown in Figure 40. Secure coolant hoses (9) and () using nylon cable ties. Fig. 40 4

BLUEHEAT - DODGE RAM 500 / 3500 INSTALLATION Torque all hose clamps to. Nm (5 lb-in.). To prevent coolant loss, clamp off coolant hose () going to heater core. See Figure 4. Cut vehicle coolant hose () coming from engine block () in two places. CUT Connect heater inlet hose (3) to coolant hose () from engine block with coupler (5) and two hose clamps (4). See Figure 4. Connect heater outlet hose (8) to heater core inlet hose with 90 degree coupler (6) and two hose clamps (). Fig. 4 3 4 5 Integration into Coolant System - HEMI Cut the two formed coolant hoses found in kit to.54m (5 foot) sections. Cut the 80 degree end to 90 degrees on both hoses. Removal of the air cleaner assembly will provide greater access to the inner fender well area. Cover both hoses with black conduit before installing. Fig. 4 8 6 Route Webasto heater coolant hoses (3) and (5) along passenger inner fender well. Refer to Figure 43. 9 Torque all hose clamps to. Nm (5 lb-in.). 0 Cut 90 degree bend from the heater core coolant hose () coming from the engine as shown in figure 43. Connect Webasto heater inlet hose (3) to heater core coolant hose () using 90 degree copper reducer (4) and two hose clamps (). 4 3 Disconnect OEM heater core coolant hose at connection prior to the heater core. Discard OEM section of hose, adapter, and constant pressure clamp. Fig. 43 5 Connect Webasto heater coolant outlet hose (5) to heater core coolant hose (9) using adapter/reducer and two hose clamps (0). Refer to Figure 43. 5 6 Coolant Line Connections at Heater Connect coolant inlet hose (3) from engine block to the Webasto heater circulation pump () and tighten clamp (8). Refer to Figure 44. 3 Connect coolant outlet hose (5) from heater core to coolant outlet on the Webasto heater and tighten clamp (6). Fig. 44 8 5

INSTALLATION BLUEHEAT - DODGE RAM 500 / 3500 Exhaust Install 90 degree exhaust elbow (5) onto heater () and secure with clamp (6). Refer to Figure 45. Cut exhaust tube (3) to a length of.8cm (9 inches). Connect exhaust tube (3) to 90 degree elbow (5) and secure with clamp (4). 6 Secure exhaust tube (3) to heater mounting bracket with clamp (). Bend exhaust tube (3) 90 degrees so it faces to the rear of the vehicle and down. Fig. 45 5 4 3 Fuse Tap Connection - Relay K Route the blue fuse tap wire (9) to fuse panel () as shown in Figure 46. 8 9 With a test light, find an Ignition ON power source. Test light must be off when ignition key is in the OFF position. Using the supplied fuse tap connector, tap into the fused side of the selected fuse (8) as shown in Figure 46. Fig. 46 Power Connection Connect red power lead (0) to existing stud () in front of fuse block () as shown in Figure 4. 0 Concluding Work Install all vehicle parts, panels and components removed during heater installation. Fig. 4 Check that all hose lines, hose clamps and pipe clips and all 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. Turn to Final Inspection and Initial Start-up. 6

BLUEHEAT - DODGE RAM 500 / 3500 INSTALLATION Final Inspection and Initial Start-up 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 chaffing and related damage. loose fuel line clamps. routing of fuel lines and fuel lines securely tied and protected against chaffing and related damage. loose wiring connections and battery connections. routing of wiring harness and wiring harness securely tied and protected against chaffing 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) and switch off air conditioning system. 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. No further start attempts are possible until the control unit lockout condition is cleared. 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. Coolant temperature must be below 30 C (86 F) before heater will attempt to start. 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.

INSTALLATION BLUEHEAT - DODGE RAM 500 / 3500 Basic Troubleshooting CAUTION Troubleshooting requires comprehensive knowledge about structure and theory of operation of the heater components and may only be performed by Webasto trained and certified, professionals. General Information This section describes troubleshooting procedures for the BlueHeat coolant heater within the scope of installation. Troubleshooting is normally limited to the isolation of defective components and provides information on defective wiring and connections. Should the heater not function after completing the installation and initial start-up instructions, refer to the following troubleshooting instructions and information to isolate and remedy the cause for malfunction. In the event you are unable to remedy a malfunction after following these troubleshooting instructions or for unanticipated malfunctions beyond what is covered in this troubleshooting section, please contact one of our Webasto Technical Assistance Representatives for further instructions. In the USA, call (800) 555-458 In Canada, call (800) 66-8900 Before troubleshooting, check for and eliminate the following probable causes for trouble: power supply to heater is less than 0.5 volts at main power connections (charge batteries and perform load test). 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. shut down initiated by temperature limiter. heater control unit locked out. Refer to Heater Lockout Reset Procedure. After correction of a malfunction, a functional test has to be performed with heater installed on the vehicle. 3. Heater Lockout Reset Procedure The BlueHeat is designed with a lockout safety feature built in to 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. Before troubleshooting the heater, ensure heater is not in the Lockout mode by performing the following reset procedure:. Ensure timer or switch is in the off position. Turn timer or switch to the on position. Remove main fuse F (0 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 in 0 seconds after inserting fuse. 8 Coolant must be below 60 C (40 F) before heater will attempt to start.

BLUEHEAT - DODGE RAM 500 / 3500 INSTALLATION General Malfunction Symptoms The following table lists possible malfunction symptoms. Malfunction Symptom Coolant heater switches off automatically (Fault lockout) Probable Cause No combustion after start or automatic repeat start Flame extinguishes during operation Heater overheats Vehicle electrical system voltage too low Remedy Switch off heater momentarily and switch on once again Switch off heater momentarily and switch on once again Check coolant lines for obstructions, closed valves and kinks. Check coolant level. Allow heater to cool down, reset overheat limiter, switch off heater momentarily and switch on once again Charge battery Switch off heater momentarily and switch on once again Heater expels black fumes from exhaust Table : Combustion air and/or exhaust ducting blocked General Malfunction Symptoms Check combustion and exhaust ducting for obstructions PC Diagnostics Interface Kit CAUTION Diagnostics equipment is intended for use by Webasto trained personnel at authorized Webasto Distributor, Dealer and End User service facilities. A PC Diagnostic Interface kit for the BlueHeat is available that allows for more thorough testing and troubleshooting of the heater and its components beyond the scope of this installation manual. The diagnostic kit makes it possible to read and remove (reset) stored malfunction codes from the BlueHeat memory. The PC Diagnostic Interface Kit comes complete with connecting hardware, software and instructions for use with any IBM/PC compatible computer. Also available are several interface connectors for use with Webasto heaters equipped with internal diagnostic capabilities such as the BlueHeat. In addition to working with stored malfunction codes, the PC Diagnostics Interface Kit allows you to perform several other functions such as reading values while the heater is in operation or testing individual components. Printing out malfunction codes is also available (User supplied printer required). For further capabilities and instructions for use with the BlueHeat heater, see the instruction manual supplied with the PC Diagnostics Interface Kit. Order PC Diagnostics Interface Kit under part number 954F. Kit does not include required adapter for the BlueHeat and must be included in your order. Order adapter under part number 9566A. 9

INSTALLATION BLUEHEAT - DODGE RAM 500 / 3500 Heater Harness Schematic - Heater Control Portion 0

BLUEHEAT - DODGE RAM 500 / 3500 INSTALLATION Heater Harness Schematic - Blower Control Portion

INSTALLATION BLUEHEAT - DODGE RAM 500 / 3500 Heater Plumbing Schematic - Inline Method

Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-458 Canada: (800) 66-8900 Org. 0/00 Rev. 0/004 P/N 500068B www.webasto.us www.techwebasto.com