BlueHeat AirTop 000 Heater Air Heater Installation Manual Ford E-Series 6.0L Diesel Beginning Model Year: 006 Special instructions for these models Part locations may differ slightly dependent on the vehicle model. Be sure to check WWW.techwebasto.com for the latest addition of this manual. Special Tools Torque Wrench Table of Contents Foreword Parts List Vehicle Information Scope and Purpose Symbol Identification 4 General References 5 Preparation 5 Heater Installation Site 5 Installation Component Break-down - (Typical) 6 Universal Mounting Plate 7 Mounting the Air Top 000 Heater 8 Integration into Fuel System 0 Exhaust Routing and Installation Combustion Air Intake Installing the Electrical Harness 4 Rheostat Control Dial Installation (Standard) 4 Optional Timer Installation 4 Power and Ground Connections 5 Optional Timer Wiring Diagram 6 Wiring Schematic - Optional Timer 7 Wiring Schematic - Rheostat Control Dial 8 Concluding Work 9 Heater Maintenance 0 DOC. P/N 500B KIT P/N 5008B Printed in USA Webasto Product N.A., Inc.
Warning 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 WARN- INGS. Never install the heater in enclosed areas where combustible fumes may be present. Webasto rejects any liability for problems and damage caused by the system being installed by untrained personnel or by improper installation. Improper installation or installation by untrained personnel voids all warranties on this product. If there are any questions regarding the installation or maintenance of this product, please call technical support at -800-555-458.
Parts List Quantity Part Part Number Air Heater 5005B Installation Kit 5008B Vehicle Information Manufacturer Model Year Engine Type Ford Econoline Beginning 006 6.0 Liter - Diesel Foreword This installation requires special expertise from a Webasto training course to install a Webasto Air Top 000, which means that it may only be installed by a specially trained workshop or dealership. 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 distributors, dealers and personnel in the installation of the Air Top 000 and BlueHeat 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 Air Top 000 must be followed. Acknowledged engineering conventions must be observed for the installation work. CAUTION Location of heater, 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. All relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary heating devices must be observed!
BlueHeat TM Ford E-Series Symbol Identification Symbols that define sections in manual Mechanical Preparation Exhaust Electrical Combustion Air Intake Fuel General Symbol Descriptions Warning Refer to Webasto or Manufacturer Manual Caution Attention Flammable or Combustible Line of Sight/Item Location on Vehicle 4
BlueHeat TM 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. Heater Installation Site For this application the Webasto Air Top 000 was mounted to the floor of the vehicle, forward of the right-rear wheelhouse. Installation of the heater is not limited to this location. However, the heater must be securely mounted in a location which provides a good seal from the exterior of the vehicle. () Webasto Air Top 000 Heater Fig. 5
BlueHeat TM Component Break-down - (Typical) Some components may be different or not included in the vehicle specific kit purchased. 6
BlueHeat TM Ford E-Series Universal Mounting Plate A mounting template has been included with the heater kit for ease of installation. The template details all required hole locations and clearances. Also, check for clearance around sub-floor cross-members, structures and heat sensitive components before proceeding with installation. 8 mm (5/6 in.) Drill Bit 00 mm (4 in.) Hole NOTE: ALLOW 55mm (6 in.) CLEARANCE FOR DUCTING TEMPLATE NOT TO SCALE 7
Mounting the Air Top 000 Heater CAUTION Always check for obstructions under vehicle before drilling. Remove obstructions if necessary. Using a hole saw or similar large hole cutter, cut a 00 mm (4 in.) hole in the center of the template outline. Use a 8 mm (5/6 in.) drill bit to drill mounting holes. () Heater template Fig. Temporarily place the heater mounting plate in position and insert 4 locator bolts through plate. Cut the flooring material using the heater mounting plate as a template. Remove the mounting plate and flooring material. () Flooring material Fig. Install gasket on heater as shown in Figure 4. () Bottom of heater () Gasket Fig. 4 8
Install heater mounting plate on heater and apply foam seal. () Foam seal () Heater mounting plate () M6 nut / washer assembly Fig. 5 4 Fig. 6 The exhaust tube can also be installed on the heater at this time. Refer to Exhaust Routing and Installation on page. Install air intake tube and fuel line coupler on heater before mounting heater to floor. () #0 hose clamp () Air intake tube () 90 fuel coupler shown (use straight coupler for E -Series) (4) 0mm fuel line clamp CAUTION Torque all mounting bolts evenly. Do not overtighten mounting fasteners! Mounting plate distortion may occur resulting in fan motor failure. Ensure the heater base and gasket covers the entire hole. Mount Heater / Plate Assembly to vehicle using 6 mounting bolts and locknuts. () Heater () M6 mounting bolt, M6 locknut - 6 ea. Fig. 7 9
Integration into Fuel System Ensure the fuel lines are fully seated within the fuel line couplers and any 90 degree bends are not buckled. Refer to Figure 8. Tighten all fuel line clamps to.0 -.4 Nm (8.8 -.4 lb.-in.) Fig. 8 4 Auxiliary Fuel Pickup Connection The sending unit shown may look different than the one installed on the vehicle, but the procedure for installing the fuel pickup is the same. 6 5 Fig. 9 Lower vehicle fuel tank in order to access fuel sending unit. Remove cap from auxiliary fuel pickup tube and install 90 degree fuel coupler provided. Connect heater fuel line to fuel line coupler and tighten hose clamps. Secure heater fuel line to vehicle fuel line with cable ties. () 90 fuel line coupler () Axially fuel pickup tube () Fuel sender (4) Vehicle fuel line (5) Heater fuel line (6) 0mm fuel line clamp (-ea.) Fuel Pump Installation Mount the fuel pump using an existing hole in the left framerail. See Figure 0 for location. () P-clamp, M6x0 bolt, and M6 nut () Fuel pump () Left framerail Fig. 0 0
5 4 Fig. 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. Route the heater fuel line from the auxiliary fuel pickup tube to the inlet side of the fuel pump (cut to length) and connect using fuel line coupler and clamps. Connect the remaining section of fuel line to the outlet end of the fuel pump using the fuel line coupler and clamps. () Outlet fuel line coupler () Fuel pump () Inlet fuel line coupler (4) 0mm clamp - (4 ea.) (5) Fuel line from auxiliary fuel pickup Route fuel line from fuel pump outlet to the passenger side of the vehicle under vehicle crossmember. Secure fuel line with cable ties. () Vehicle crossmember () Fuel line with plastic loom () Cable tie Fig. Route fuel line from the crossmember to the heater mounting location and connect to heater with fuel line coupler installed previously. () Fuel line coupler () Fuel line () 0mm clamp Fig.
Connect fuel pump harness to fuel pump extension harness. () Fuel pump harness () Fuel pump extension harness Fig. 4 Route the fuel pump extension harness to the fuel pump mounting location following the fuel line. Secure the wiring harness to the vehicle with cable ties. () Vehicle crossmember () Fuel pump electrical harness () Heater fuel line Fig. 5 Connect fuel pump harness electrical harness to fuel pump. () Fuel pump harness () Fuel pump Fig. 6
4 Fig. 7 Exhaust Routing and Installation Install exhaust tube (pre-cut to 508 mm or 0 in.) on heater and route as shown in Figure 7. Secure exhaust tube to heater mounting bolt with P-clamp, washer and nut provided. Position exhaust insulator on exhaust tube to prevent exhaust tube from contacting vehicle underbody. () Exhaust insulator () P-clamp, washer, and M6 nut () Exhaust tube (4) Exhaust clamp Ensure end of exhaust tube is pointing downwards and towards the rear of the vehicle. Secure exhaust tube with p-clamp as shown in Figure 8. () Exhaust tube () P-clamp, M6x0 bolt and M6 nut Fig. 8 Combustion Air Intake Route combustion air Intake tube over framerail. () Combustion air intake tube Fig. 9 Ensure end of air intake tube is pointing downwards and towards the rear of the vehicle. Bend end of air intake tube down and secure with cable tie as shown in Figure 0. () Air intake tube () Right framerail () Cable tie Fig. 0
Fig. Fig. Installing the Electrical Harness Remove top access cover from heater and plug the harness into the control unit receptacle socket as shown. Check your wiring! Ensure that all connections have been done in accordance with the wiring diagrams located in the back of this book. Sensitive electronic controls can be damaged if wired incorrectly! () Air Heater () Heater wiring harness Rheostat Control Dial Installation (Standard) CAUTION Check behind panels for obstructions before drilling holes. Before installing the heater control, please confirm the installation location with the customer. Install rheostat control, refer to Figures and for correct installation, and connect wiring harness. Secure wiring harness with cable ties. Correct The optical fiber must be in contact with the rotary knob. Incorrect Optional Timer Installation The optional 7 day timer can be installed in place of the rheostat switch (heater control) that comes standard with the air heater. Fig. CAUTION Check behind panels for obstructions before drilling holes. Before installing the timer, please confirm the installation location with the customer. Secure wiring harness with cable ties. Wire timer harness connector in accordance with the wiring diagram located on page 6. Route timer harness between inner and outer body panels to timer location. See Figure 4. Using timer mounting bracket as a template, drill two holes in inner body panel and install timer. 4 Fig. 4 () Cable tie () Timer mounting bracket () Timer control (4) Inner body panel 4
4 Fig. 5 Power and Ground Connections Apply silicone sealant to grommet after routing power and ground wires. Route heater and timer power and ground wires through body grommet shown in Figure 5. Secure power and ground wires to heater mounting bolt with p-clamp. () P-clamp () Heater mounting bolt () Power and ground wires (4) Body grommet Secure the power circuit fuse holder and excess fuel pump harness between the vehicle batteries using cable ties. () Right framerail (between batteries) () Power circuit fuse holder () Fuel pump harness Fig. 6 4 Fig. 7 Lower battery tray to gain access to vehicle batteries. Secure heater and timer power wires to battery positive terminal. Secure heater and timer grounds to negative battery terminal. () Heater and timer power wires () Battery positive terminal () Heater and timer ground wires (4) Battery ground terminal Raise and secure vehicle battery tray. Ensure the ground lead going to the framerail is tightened to 5 Nm (8 lb-ft). 5
BlueHeat TM Optional Timer Wiring Diagram Battery Positive (0) Battery Negative (4) (ground) Dash Lights () (optional) Battery Positive () Battery Negative () (ground) Battery Negative (4 & ) Black () Blue (6) Red (8) White (9) BlueHeat with optional timer 8806A (7-Day Digital Timer Model 5 with Temperature Rheostat) 6
BlueHeat TM Ford E-Series Wiring Schematic - Optional Timer 7
BlueHeat TM Wiring Schematic - Rheostat Control Dial Rheostat Control Dial Fuel Pump 8
Concluding Work. Install all vehicle parts, panels and components removed during heater installation.. Secure all loose lines and cables with nylon cable ties.. Spray the heater components and electrical connections with an anti-corrosive wax coating. Final Inspection Inspect installation for: loose fasteners. Exhaust system routing and clamp tightness. Combustion air intake tube routing and clamp tightness. 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. Initial Start-up. Set time and day of week on heater timer according to operating instructions found in the owners manual.. Switch on the Webasto heater by means of the instant heat button on timer and check: Timer panel and instant heat indicator illuminates. Initiation of start-up sequence. Successful start-up and operation (heat produced at heater outlet). 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 and runs successfully. Should the heater fail to start or operate correctly, call your Webasto technical representative at: -800-555-458 9
Heater Maintenance The Webasto BlueHeat heater is designed for minimal maintenance. Under normal circumstances it should be inspected for proper function at least once annually, preferably, just prior to the heating season. To ensure trouble-free operation, the following should be part of an annual and periodical inspection:. Operate the heater a minimum of 0 minutes every month to keep fresh fuel in the system and the fuel pump lubricated.. Keep the heating air outlet clear of obstructions.. Keep the heater inlet grille clear of obstructions. 4. Inspect the combustion air tube and exhaust tube for obstructions and damage. Check to ensure they are securely attached to the heater and vehicle. Repair damaged items where necessary. 5. Inspect the fuel system and all connections for leaks. Tighten clamps if loose. Ensure fuel line is well secured to the vehicle. Replace fuel filter if equipped. 0
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Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-458 Canada: (800) 667-8900 Org.0/006 Rev. 06/006 P/N 500B www.webasto.us www.techwebasto.com