Table of Contents
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BlueHeat
Thermo Top
1
3
2
Legend
1 Fuse Holder, Relays and Resistor Assembly
2 Timer Control
3 BlueHeat Coolant Heater, Exhaust Tube, and Combustion Air Intake Silencer
4 Fuel Pump
Special Tools
- Hose Clamping pliers
- Torque Wrench
Table of Contents
Installation
DOC P/N 5001274A
KIT P/N 5001273A
Coolant Heater
4
3
3
3
4
5
5
5
6
7
7
8
8
9
11
12
Printed in USA
GMC Sierra 2500 HD
GMC Sierra 3500 HD
6.6 Liter Duramax Diesel
Beginning Model Year: 2000
Chevrolet Silverado 2500 HD
Chevrolet Silverado 3500 HD
6.6 Liter Duramax Diesel
Beginning Model Year: 2000
Special instructions for these models
Part locations may differ slightly dependent on
the vehicle model.
13
13
13
14
16
16
16
18
20
22
23
24
25
26
27
28
Webasto Product N.A., Inc.
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Table of Contents
Related Manuals for Webasto BlueHeat Thermo Top
Summary of Contents for Webasto BlueHeat Thermo Top
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Page 1: Table Of Contents
3-Relay HVAC Harness Connections Electrical Harness Schematic - Part 1 Heater Preparation Electrical Harness Schematic - Part 2 Heater Installation Site Preparation Heater Plumbing Schematic - Inline Method DOC P/N 5001274A KIT P/N 5001273A Printed in USA Webasto Product N.A., Inc. -
Page 2: Electrical Harness Schematic - Part
Webasto training, technical information, special tools and special equip- ment. • 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 prop- erly complete the necessary procedures. -
Page 3: Foreword
Failure to comply with all installation instructions is a misuse of Webasto products. The same applies for repairs without using genuine Webasto service parts. This will void the coolant heaters “official Marks of Conformity.”... -
Page 4: Symbol Identification
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD 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
– Remove instrument panel fascia for timer mounting. Refer to vehicle manufacturers instructions for fascia removal. – Protect vehicle fenders, panels and interior with covers Heater Installation Site Mount the Webasto auxiliary heater on the left framerail just below the drivers compartment. – (1) Webasto Auxiliary Coolant Heater (Installed) Fig. 1... -
Page 6: Electrical - Overview
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD Electrical - Overview ATTENTION The routing of cables and wires are done in accordance to the general valid rules of engineering. If not described differently, securing of wiring and cables is done with cable ties to the vehicle’s own wires and cable harnesses. ATTENTION Timer control location is a recommendation only. -
Page 7: Electrical Harness
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD Electrical Harness ATTENTION Cut wire tie holding negative-side blower harness (with relay) from main harness and set aside. To attach fuse holder to bracket, a 6.0 mm (1/4 in.) can be drilled through the bracket. -
Page 8: Fuse Tap Connection - Relay
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD ATTENTION Before installing the timer, please confirm the installation location with the customer. – (1) Timer - Sample location only Fig. 6 Fuse Tap Connection - Relay K-1 Locate a fuse (15 to 20 amp) in the underhood fuse / relay center that is “HOT”... -
Page 9: 3-Relay Hvac Harness Connections
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD 3-Relay HVAC Harness Connections Webasto Vehicle NOTE: It is permissible to cut excess length from Webasto HVAC wiring harnesses to fit the application. “ ” Cut motor wires where indicated by – (1) Chassis ground –... - Page 10 GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD Heater Control Harness Routing CAUTION Secure heater control harness away from hot exhaust components and moving vehicle components with cable ties. Route heater control harness from the engine compartment to the left framerail. Keep heater harness away from the exhaust system and the steering shaft.
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Page 11: Heater Preparation
Cut supplied hoses as shown in Figure 15. Hose A: From engine to coolant pump inlet =175 cm (69 inches). Hose B: From Webasto heater outlet to vehicle heater core inlet = 185 cm (73 inches). Fig. 15 – (A) Heater inlet (supply) hose with 90 degree turn –... -
Page 12: Heater Installation Site Preparation
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD ATTENTION Observe torque specifications. Connect coolant hoses and fuel line coupler to heater as shown in Figure 17. – (1) Heater inlet “A” hose with 90 degree turn – (2) Heater outlet “B” hose –... -
Page 13: Heater Installation (Underbody Mount)
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD Heater Installation Mount the heater and mounting bracket assembly on the left framerail with 3 screws provided. – (1) Heater and mounting bracket assembly – (2) Left framerail Fig. 21 Fig. -
Page 14: Integration Into The Coolant System
Coolant flow and connection detail: Hose A: From engine to Webasto coolant pump inlet. Hose B: From Webasto heater outlet to vehicle heater core inlet. NOTE: Also see the plumbing schematic, page 31, of this manual for a general outline of the coolant circuit... - Page 15 – (1) Webasto coolant hose returning from heater outlet to vehicle heater core inlet (hose “B”) – (2) Webasto coolant hose leading from engine to heater circulation pump inlet (hose “A”) Fig. 29 – (3) Heater core supply hose...
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Page 16: Integration Into The Fuel System
Use the existing vehicle fuel line clips to secure the heater fuel line to the vehicle. – (1) Existing vehicle fuel line clip – (2) Mecanyl fuel line – (3) Left framerail – (4) Webasto heater location Fig. 33... - Page 17 GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD Continue routing the mecanyl fuel line toward the heater. Use existing vehicle clips and cable ties to secure the fuel line to the vehicle. – (1) Mecanyl fuel line (heater) –...
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Page 18: Standpipe Installation - 2000 Through 2003
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD Standpipe Installation - 2000 Through 2003 Model Years CAUTION For reasons of safety due to the weight of fuel and the tank, it is recommended that there be no more than 1/4 tank fuel present. - Page 19 GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD – (1) M8 locking nut Torque to 8.5-9.5 Nm (75-84 lb-in.) – (2) Holding fixture (not required) Re-install fuel sender assembly according to the vehicle manufacturers servicing instructions. Fig. 40 Connect fuel line to fuel sender.
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Page 20: Standpipe Installation - 2004/2006 Model Year
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD Standpipe Installation - 2004 - 2006 Model Year CAUTION For reasons of safety due to the weight of fuel and the tank, it is recommended that there be no more than 1/4 tank fuel present. - Page 21 GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD Cut standpipe to length. The standpipe tube should terminate approximately 38 mm (1.5 in.) off bottom of tank when installed. Refer to Figure 47 for length. Remove any burrs from inside cut end of tube. Bend standpipe as shown.
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Page 22: Fuel Line Routing From Sender To Pump
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD Legend for Figure 49 1 Banjo Bolt - Torque 8.5-9.5 Nm (75-84 lb-in.) 2 Banjo Fitting 3 Standpipe 4 Upper Sealing Washer (Black) 5 Fuel Tank 6 Lower Sealing Washer (Brass) 7 Lock Nut - Torque 8.5-9.5 Nm (75-84 lb-in.) Fig. -
Page 23: Power Connection
Power Connection Connect red power lead to existing auxiliary power point underhood. Connect brown ground lead as shown. Reconnect battery ground cable. – (1) Vehicle auxiliary power point – (2) Webasto power lead – (3) Webasto ground lead Fig. 55... -
Page 24: Final Inspection Initial Start-Up And 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 25: Heater Lockout Reset Procedure
ATTENTION – The engine coolant must be below 86 °F (30 °C) before the Webasto heater will attempt to start. – Should the heater fail to start or operate correctly, contact your Webasto technical representative at:... - Page 26 BlueHeat GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD Electrical Harness Schematic - Part 1, Heater Control...
- Page 27 GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD BlueHeat Electrical Harness Schematic - Part 2, HVAC Blower Control...
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Page 28: Heater Plumbing Schematic - Inline Method
BlueHeat GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD Heater Plumbing Schematic - Inline Method... - Page 29 What could be added or clarified? Please list any other comments, concerns, or suggestions. Please provided contact information below. Name: Company Name: Mail to: Webasto Product N. A., Inc. City / State: 15083 North Road Fenton, MI 48430 Phone: Attention: Documentation Group...
- Page 30 Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org. 10/2006 Rev. N/A P/N 5001274A www.techwebasto.com...
- Page 31 GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD BlueHeat Sender Unit / Standpipe Template for Model Year 2004/05 Vehicles Cut out along solid outline of template. 2004/05 Vehicles with metal fuel sender unit. Cut out along solid outline of template. 2004/05 Vehicles with metal fuel sender unit.
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