Webasto BlueHeat Manual
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Webasto BlueHeat Manual

Webasto BlueHeat Manual

Vw passat
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Download this manual See also: Instruction and Installation Manual
BlueHeat
Thermo Top
2
1
3
Legend
1 BlueHeat Coolant Heater, Exhaust Tube, and Combustion Air Intake Silencer
2 Fuse Holder, Relays and Resistor Assembly
3 Timer Control
4 Fuel Pump
Special Tools
- Hose Clamping pliers
- Torque Wrench

Table of Contents

Installation
DOC P/N 5001063A
KIT P/N 5001062B
Coolant Heater
4
3
3
3
4
5
5
5
6
7
8
8
9
10
11
11
12
Printed in USA
VW Passat
Beginning Model Year: 2005
Special instructions for these models
Part locations may differ slightly dependent on
the vehicle model.
13
15
16
16
16
17
17
17
18
18
18
19
20
21
22
23
Webasto Product N.A., Inc.

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Summary of Contents for Webasto BlueHeat

  • Page 1: Table Of Contents

    Special instructions for these models Part locations may differ slightly dependent on the vehicle model. Legend 1 BlueHeat Coolant Heater, Exhaust Tube, and Combustion Air Intake Silencer 2 Fuse Holder, Relays and Resistor Assembly 3 Timer Control 4 Fuel Pump Special Tools –...

  • Page 2: Electrical Harness Schematic - Part

    – 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.

  • Page 3: Foreword

    This installation requires special expertise from a Webasto training course to install a Webasto Thermo Top heater, 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

    VW Passat 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

    – Protect vehicle fenders, panels and interior with covers Heater Installation Site ATTENTION The Webasto Auxiliary Coolant Heater is installed on the left side of the engine next to the vehicle ABS unit. – (1) Webasto Auxiliary Coolant Heater (Installed)

  • Page 6: Electrical - Overview

    Timer control location is a recommendation only. Please consult with the customer before mounting. Fuse Block/Relays/Resistor HVAC Blower Motor (1) Fuse Holder (1) Blower Control Integration (2) Relays (2) Glove Box Area Digital Timer (Sample Location) Fuel Metering Pump (1) Webasto Digital Timer (1) Fuel Metering Pump (2) Right Rear Side of Vehicle...

  • Page 7: Electrical Harness

    VW Passat Electrical Harness ATTENTION Cut wire tie holding negative-side blower harness (with relay K3) from main harness and set aside. Bend electrical mounting bracket as shown in Figure 2. Mount heater electrical components to bracket and secure bracket to vehicle with existing nut. –...

  • Page 8: Timer Installation

    VW Passat Timer Installation CAUTION Check behind panels for obstructions before drilling holes. ATTENTION Before installing the timer, please confirm the installation location with the customer. Affix supplied template to panel. Drill 10 mm (25/64 in.) and 2.5 mm (3/32 in.) holes where indicated on template.

  • Page 9: 3-Relay Hvac Harness Connections

    VW Passat 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 – (2) Splice green wire to green wire –...

  • Page 10: Heater Preparation/Installation

    The relay shown in Figure 13 will have to be relocated in order to mount the Webasto heater. Remove bolt securing relay to vehicle and relocate relay to engine cover stud. See Figure 14.

  • Page 11: Integration Into The Fuel System

    VW Passat Integration into the Fuel System Standpipe Installation ATTENTION The vehicle fuel sender can be accessed from inside the vehicle. Remove the fuel sender from the vehicle following the manufactures service instructions. – (1) Behind rear passenger seat – (2) Fuel sender Fig.

  • Page 12: Fuel Pump Installation

    VW Passat Standpipe Installed ATTENTION Ensure fuel sender travel is not impeded by standpipe installation. Position standpipe in fuel sender cup during installation. – (1) Standpipe – (2) Fuel sender cup Fig. 19 Install fuel sender following the manufacture’s service instructions.

  • Page 13: Fuel Line And Electrical Harness Routing

    VW Passat Connecting Fuel Line to Fuel Pump ATTENTION 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. Pre-assemble fuel line couplers on fuel pump before installation.
  • Page 14 VW Passat Route the Mecanyl fuel line across the engine compartment toward the left side of the engine. – (1) Mecanyl fuel line Fig. 27 CAUTION Ensure the Mecanyl fuel line and fuel pump electrical harness are secured away from the vehicle’s exhaust components.

  • Page 15: Integration Into The Coolant System

    Connect the 90 degree end of hose “B” to the coolant hose going to the heater core. 305 mm 368 mm Hose A: From engine block to Webasto coolant pump inlet. – Hose B: From Webasto heater outlet to vehicle heater core. NOTE: Also see the plumbing schematic, page 23, of this manual for a general outline of the coolant circuit arrangement.

  • Page 16: Webasto Heater Hose Integration Point

    VW Passat Hose Connections at Heat Exchanger ATTENTION Determine coolant flow before cutting coolant hoses. The Webasto heater is plumbed inline with the heater core supply hose. – (1) Heater core return hose – (2) Heater core supply hose Fig. 30...

  • Page 17: Heater Mounting Site

    Mount heater on vehicle with existing hardware and two self-tapping screws provided in kit. Connect heater control harness at this time. – (1) Webasto heater – (2) Existing bolt and washer – (3) Heater control harness Fig. 36 Air Intake Silencer Installation Install air intake silencer on silencer tube.

  • Page 18: Exhaust System Installation

    VW Passat Exhaust System Cut the exhaust tube as shown in Figure 38. – (a) Exhaust tube = 838 mm (33 inches) – (b) Tailpipe = 102 mm (4 inches) Fig. 38 ATTENTION Keep exhaust tube away from heat sensitive vehicle components.

  • Page 19: Final Inspection Initial Start-Up And Concluding Work

    2 Set interior heater control to maximum heat position (hot), fan speed between low and maximum, 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 20: Heater Lockout Reset Procedure

    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 21 VW Passat Electrical Harness Schematic - Part 1, Heater Control...
  • Page 22 BlueHeat VW Passat Electrical Harness Schematic - Part 2, HVAC Blower Control...

  • Page 23: Heater Plumbing Schematic - Inline Method

    BlueHeat VW Passat Heater Plumbing Schematic - Inline Method...
  • Page 24 VW Passat...
  • Page 25 VW Passat...
  • Page 26 Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org. 04/2005 Rev. N/A P/N 5001063A www.techwebasto.com...

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