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Webasto BlueHeat Installation Instructions Manual

For lexus 2004 rx330
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BlueHeat
2004 Lexus RX330
3.3 Liter V-6

Installation Instructions

– 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 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.
Coolant Heater
DOC P/N 5000684A
KIT P/N 5000655B

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Summary of Contents for Webasto BlueHeat

  • Page 1: Installation Instructions

    – 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 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.

  • Page 2: Table Of Contents

    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 2004 Lexus RX330, 3.3 liter gasoline version, unless technical modifications on the vehicle influence the installation, excluding all liability claims.

  • Page 3: Heater Installation Site

    2004 Lexus RX330 3.3 Liter V-6 BlueHeat Heater Installation Site The Webasto BlueHeat auxiliary coolant heater is to be installed at the left front corner, behind the bumper as shown in the illustration below. Mounting Location Fig. 1 Mounting Location Heater Installed Fig.

  • Page 4: Installation

    2004 Lexus RX330 3.3 Liter V-6 Installation Heater Preparation Position 1 and 2: – Fasten bracket to heater using 2 M6 self-tapping EJOT screws. – Torque screws to 10 Nm. (88.5 lb-in.). Fig. 3 Position 3 and 4: – Relocate ground splice to location shown. Fig.

  • Page 5: Electrical Harness - Overview

    K1 and K2) 6 - 18 GA Blue - to Ignition ‘ON’ signal source 7 - Main Heater Harness - BlueHeat Coolant Heater 8 - Blower Control Harness - Positive side 9 - 10 GA Red - Connects to HVAC control switch...

  • Page 6: Fuse Holder / Relays / Resistor

    2004 Lexus RX330 3.3 Liter V-6 Fuse Holder / Relays / Resistor ATTENTION The electrical harness is a two-part assembly. Before installing, cut wire tie holding the negative side HVAC blower harness (with relay K3) to the main harness and separate.

  • Page 7: Integration With Hvac Blower Motor

    Fig. 13 Additional Legend for Figure 6 – Secure HVAC blower control wiring to vehicle A From Webasto Heater X1 structures with nylon wire ties (Image not available) B 12 VDC ignition ‘On’ fuse tap C HVAC control module M HVAC blower motor X Cut wire 50 mm (2 in.) from HVAC motor...

  • Page 8: Timer Installation - Model 1533

    2004 Lexus RX330 3.3 Liter V-6 Timer Installation - Model 1533 ATTENTION Before installing the timer, please confirm the installation site with your customer. CAUTION Before drilling into any panels, ensure there are no hidden components behind the panel that may be damaged or interfere with the timer installation! If Fig.

  • Page 9: Integration Into The Fuel System

    2004 Lexus RX330 3.3 Liter V-6 Integration into the Fuel System WARNING Full to partially filled fuel tanks are heavy and awkward to handle. Before removing fuel tank to gain access to the sender unit, ensure tank is near empty. To avoid accidents and injury to personnel, make sure tank is well supported while removing mounting hardware.

  • Page 10: Fuel Metering Pump Installation

    2004 Lexus RX330 3.3 Liter V-6 Legend for Figure 20 4 Standpipe 5 Upper Sealing Washer 6 Lower Sealing Washer 7 Lock Nut 8 Fuel Tank Sender Unit Position 4 and 7 Fig. 20 – Install fuel standpipe with outlet aligned as shown. –...

  • Page 11: Fuel Line And Cable Installation

    2004 Lexus RX330 3.3 Liter V-6 CAUTION Ensure fuel line does not come into contact with hot exhaust components or other sources of extreme heat. Ensure fuel line is kept away from moving parts. ATTENTION Fuel line must be cut using a sharp razor knife or razor. DO NOT cut with side cutters, scissors or similar tools as doing so will cause a restriction inside the fuel line.

  • Page 12: Integration Into The Coolant System

    2004 Lexus RX330 3.3 Liter V-6 Integration into the Coolant System NOTE: For an overview of the coolant circuit, turn to the back section of this manual for a plumbing schematic. NOTE: Torque all hose clamps to 1.5 - 2.0 Nm (13 - 18 lb-in.). Position 1, 2 and 3 Preparing –...

  • Page 13: Exhaust System

    2004 Lexus RX330 3.3 Liter V-6 Exhaust System Exhaust Position 1and 2 System – Install 90 degree exhaust elbow on heater. – Tighten clamp to 5 - 5.5 Nm (44 - 49 lb-in.) Fig. 32 Position 3 and 4 – Remove 216mm (8.5 in.) from exhaust tube. –...

  • Page 14: Combustion Air Intake Installation

    2004 Lexus RX330 3.3 Liter V-6 Combustion Combustion Air Intake Installation Air Intake Position 1 and 2 – Install split end of combustion air intake tube on heater with narrow band hose clamp. Fig. 36 Position 1 and 3 ATTENTION The silencer must be pointed in a downward direction! –...

  • Page 15: Concluding Work

    2. 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: •...
  • Page 16 2004 Lexus RX330 3.3 Liter V-6...

  • Page 17: Basic Troubleshooting

    Heater Lockout Reset Procedure The BlueHeat 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.
  • Page 18 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.

  • Page 19: Wiring Schematic - Part 1

    Schematics 2004 Lexus RX330 3.3 Liter V-6 Wiring Schematic - Part 1...

  • Page 20: Wiring Schematic - Part 2

    2004 Lexus RX330 3.3 Liter V-6 Schematics Wiring Schematic - Part 2...

  • Page 21: Plumbing Schematic

    Schematics 2004 Lexus RX330 3.3 Liter V-6 Plumbing Schematic...
  • Page 22 Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org. 07/2003 P/N 5000684A www.techwebasto.com...

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