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BlueHeat
AirTop 2000 Heater Installation Manual
Required Tools
- 1/4" Drive Ratchet
- 1/4" Drive 4 inch extension
- 10 mm six point socket, 1/4" drive
- 10 mm six point deep well socket, 1/4" drive
- 3/8" Drive Ratchet
- 3/8" Drive 12 inch extension
- 13 mm socket, 3/8" drive
- 15 mm socket, 3/8" drive
- 17 mm socket, 3/8" drive
- 10 mm combination wrench
- 8 mm nut driver
Table of Contents
DOC P/N 5000712A
KIT P/N 5000389B
AirTop 2000 Heater
3
3
3
4
5
5
5
6
7
8
Printed in US
Webasto Product N.A., Inc.
Dodge Sprinter
(Passenger Van)
2003 2.7 Liter Diesel
Special instructions for these models
Part locations may differ slightly dependent
on the vehicle model.
- Phillips #2 screwdriver
- Combination side-cut/crimping pliers
- Drill
- 2.5 mm (3/32 in.) drill bit
- 8 mm (5/16 in.) drill bit
- 10 mm (25/64 in.) drill bit
- Hacksaw
- Utility Knife
- Mechanic's wire - 2 feet
- Hoisting equipment and safety stands
- Vehicle manufacturer's service reference manual
9
11
12
12
17
18
19
20
21
22
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Related Manuals for Webasto blueheat airtop 2000
Summary of Contents for Webasto blueheat airtop 2000
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Page 1: Table Of Contents
Exhaust Routing and Installation Heater Installation Site Timer Wiring Diagram Installation Wiring Schematic Component Location - Overview Concluding Work Component Break-down - (Typical) Heater Maintenance Universal Mounting Plate DOC P/N 5000712A KIT P/N 5000389B Printed in US Webasto Product N.A., Inc. - Page 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.
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Page 3: Foreword
2.7 Liter - Diesel Foreword This installation requires special expertise from a Webasto training course to install a Webasto Air Top 2000, 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. -
Page 4: Symbol Identification
Dodge Sprinter Passenger Van Symbol Identification Symbols that define sections in manual Fuel Mechanical Preparation Exhaust Electrical Combustion Air Intake Coolant General Symbol Descriptions Refer to Webasto or Manufacturer Manual Warning Attention Caution Line of Sight/Item Location on Vehicle Flammable or Combustible... -
Page 5: General References
Heater Installation Site ATTENTION The Webasto Air Top 2000 Heater is to be installed on passenger side of vehicle under first row of rear seats with blower facing the rear. – (1) Webasto Air Top 2000 Heater... -
Page 6: Installation
BlueHeat Dodge Sprinter Passenger Van Installation Component Location - Overview ATTENTION Position Webasto Timer Control into vehicles auxiliary switch panel located on the center console next to the 12v power socket. Heater Cut Out Location Timer Control Location (Location) Under first row of rear seats... -
Page 7: Component Break-Down - (Typical)
Dodge Sprinter Passenger Van BlueHeat Component Break-down - (Typical) Some components may be different or not included in the vehicle specific (Dodge Sprinter Passenger Van) heater kit as shown. -
Page 8: Universal Mounting Plate
Dodge Sprinter Passenger Van BlueHeat 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-mem- bers, structures and heat sensitive components before proceeding with installation. 8 mm (5/16 in.) Drill Bit 100 mm (4 in.) Hole NOTE:... -
Page 9: Mounting The Air Top 2000 Heater
Dodge Sprinter Passenger Van Mounting the Air Top 2000 Heater – (1) Air Top 2000 Mounting Location Fig. 2 ATTENTION Using far right seat mounting bracket as a guide, position the right front corner of template 12 1/2 inches from rear of seat bracket. - Page 10 Dodge Sprinter Passenger Van ATTENTION Temporarily place the heater in position and place 4 locator bolts through the mounting plate. Cut the carpet using the heater mounting plate as a template. Remove the heater and carpet remnant. – (1) Air Top 2000 Heater –...
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Page 11: Installing The Electrical Harness
Dodge Sprinter Passenger Van Installing the Electrical Harness ATTENTION Remove top access cover from heater and plug the harness into the control unit receptacle socket as shown. Fig. 7 ATTENTION Pull back rear mat to access plywood from heater mounting location to back on front seats. -
Page 12: Timer Installation
Dodge Sprinter Passenger Van ATTENTION From the lower right side of the center console, butt splice the red and black wires added to the timer harness loom into the power connection harness. Connect the red wire to the red 12 gauge power wire and the black wire to the brown 12 gauge ground wire. - Page 13 Dodge Sprinter Passenger Van ATTENTION Route red power wire through access channel that runs under floor mat to the drivers seat. – (1) Access Channel to Drivers Seat – (2) Red Power Wire to Fuse Panel Fig. 14 ATTENTION Locate fuse panel and butt splice positive wire to the fused side of fuse 15.
- Page 14 Dodge Sprinter Passenger Van Integration into Fuel System CAUTION Fig. 17 shows correct fuel line connections versus incorrect connection. Please observe. Fig. 17 CAUTION Fuel pump MUST be mounted horizontally to function correctly. ATTENTION Prior to fuel pump installation, push rubber fuel line connectors and two clamps over each side of fuel pump damper.
- Page 15 Fig. 22 optional filter from Webasto. Order genuine Webasto fuel filter P/N 487171. The filter can be installed anywhere between the fuel tap connection and the fuel pump inlet. Typically, the filter is installed at the fuel pump inlet.
- Page 16 Dodge Sprinter Passenger Van ATTENTION Install protective loom over heater fuel line and connect line to fuel pump outlet. Route fuel line as shown through crossmember access hole and connect to the previously installed 90 degree elbow at heater. Ensure all fuel clamps have been tightened.
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Page 17: Combustion Air Intake
Dodge Sprinter Passenger Van Combustion Air Intake ATTENTION Route combustion air Intake tube from heater towards front of vehicle pointing tube end downward. Secure with supplied P-Clamps. – (1) Combustion Air Intake Tube Fig. 26 – (1) Combustion Air Intake Tube Installed –... -
Page 18: Exhaust Routing And Installation
Dodge Sprinter Passenger Van Exhaust Routing and Installation ATTENTION Route exhaust tube from heater towards rear of vehicle. Secure with supplied P-Clamps. – (1) Exhaust Tube Fig. 28 ATTENTION Ensure end of exhaust tube is pointing downwards. ATTENTION If heat insulators are used, ensure they are properly positioned and that the tail pipe is positioned downward. -
Page 19: Timer Wiring Diagram
Dodge Sprinter Passenger Van BlueHeat Timer Wiring Diagram Battery Positive (10) Battery Negative (4) (ground) Battery Positive (11) Dash Lights (1) (optional) Battery Negative (12) (ground) Black (2) Battery Negative Blue (6) (4 & 12) Red (8) White (9) BlueHeat with timer 88206A (7-Day Digital Timer Model 1531 with Temperature Rheostat) -
Page 20: Wiring Schematic
BlueHeat Dodge Sprinter Passenger Van Wiring Schematic... -
Page 21: Concluding Work
1. Set time and day of week on heater timer according to operating instructions found in the owners manual. 2. Switch on the Webasto heater by means of the instant heat button on timer and check: – Timer panel and instant heat indicator illuminates. -
Page 22: Heater Maintenance
Dodge Sprinter Passenger Van 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: 1. - Page 23 NOTES:...
- Page 24 Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 Org.10/2003 Rev. N/A P/N 5000712A www.webasto.us...
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