Fig. 902 Installing Air-Intake And Exhaust Connection Piece; Fig. 903 Installing Water Connection-Piece Variant A With Teeth; Assembling Heater - Webasto Thermo Top V Workshop Manual

Repair

9.2.2 Assembling heater

1. For information on installing new temperature sensors
(G, Fig. 901), see section 9.2.9.
2. For information on installing burner (D), see section
9.2.7.
3. Clean heat exchanger (H) inside and outside and place
on fan. Tighten screws (3) with 7 ± 0.7 Nm and do not
cut new thread if possible when doing so (i.e. turn
screw into existing thread).
4. Insert connector (K, L, M) into control unit until it audi-
bly engages. As the connectors are shape-coded, they
can be neither confused nor incorrectly poled.
5. Place connector cover (P) on control unit (Q) and
engage with light presure.
6. Insert air-intake connection piece (O) into control unit
(Q). In the process, the lug of the connection piece (O)
must be guided into the opening provided (facing in
direction of fuel connection piece). See Fig. 902.
Lug
Fig. 902 Installing air-intake and exhaust connection
piece
7. Hook heater cover at front into heater and engage in
locking lug from fan housing (T).
8. Lay new O-rings (B) into heat exchanger (H) and fasten
water connection-piece unit (A) with screw (1) and do
not cut a new thread when doing so (i.e. turn screw
into existing thread). Tightening torque 7.5 ± 0.7 Nm.
9. Fasten exhaust connection piece (J) on heat exchanger
(H) with screw (4). Tightening torque: 4.5 Nm
The work step is eliminated for the variant with a fixed
exhaust connection piece.
902
Visit www.butlertechnik.com for more technical information and downloads.
www.butlertechnik.com
IMPORTANT
When screwing on the water connection pieces and the
sensors, do not recut the thread several times. The screw
must be carefully screwed into the existing thread by hand
and then tightened with the specified torque.
IMPORTANT
Observe the different tightening torques for the screw fit-
ting of the water connection piece with teeth (4.5 Nm) and
without teeth (7.5 Nm)!
9.2.3 Installing water connection piece variants
9.2.3.1 Installing water connection-piece variant A
with teeth
Teeth
Fig. 903 Installing water connection-piece variant A with
teeth
Assemble heater as described in section 9.2.2 up to point 7.
and then install water connection piece as follows:
1. Moisten new O-rings (B, Fig. 903) with coolant and lay in
heat exchanger (H).
2. Insert water connection pieces (A1) and (A2) with retain-
ing plate (A3) in heat exchanger (H, Fig. 903).
3. Align water connection pieces in angle bracket in open-
ings of heater transfer unit and guide into teeth with
retaining plate (A3) and hold down.
4. Guide screw (1) into hole and screw on with 4.5 Nm.
Connection piece and retaining plate must be held down
while screwing on.
IMPORTANT
The O-rings and the openings of the heat exchanger must
be sufficiently moistened with coolant. Without lubricant,
the O-rings may be crushed, which results in leaks during
operation.
Thermo Top V
A2
1
H B A1 A2