Page 1: Table Of Contents
Electrical Harness Schematic - Part 1 Heater Mounting Electrical Harness Schematic - Part 2 Exhaust Installation Heater Plumbing Schematic - Inline Method Integration into the Coolant System - 6.4 Liter TT Diesel DOC P/N 5001336B KIT P/N 5001335C 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
Ford F-250/350 Super Duty Truck 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 cover for timer mounting. Refer to vehicle manufacturers instructions. – Protect vehicle fenders, panels and interior with covers Heater Installation Site Mount the Webasto auxiliary heater under the right side of the cab, behind the front tire. – (1) Webasto auxiliary coolant heater (Installed) –...
Page 6: Electrical - Overview
Ford F-250/350 Super Duty Truck Electrical - Overview ATTENTION If not described differently, secure wiring and cables with cable ties to the vehicle’s own wires and cable harnesses. ATTENTION Timer control location is a recommendation only. Please consult with the customer before mounting. HVAC Blower Motor Fuel Metering Pump (1) Blower Motor...
Page 7: Electrical Harness Installation
Ford F-250/350 Super Duty Truck Electrical Harness Installation ATTENTION Modify electrical mounting bracket as shown in Figure 2. Cut wire tie holding negative-side blower harness (with relay) from main harness and set aside. Install resistor and relays on electrical mounting bracket. –...
Page 8: Fuse Tap Connection - Relay
Ford F-250/350 Super Duty Truck – (1) Timer - recommended location only Fig. 6 Fuse Tap Connection - Relay K-1 CAUTION Tap into the “fused” output side of the selected fuse. Locate a fuse (10 to 20 amp) in the fuse / relay center that is “HOT”...
Page 9: 3-Relay Hvac Harness Connections
Ford F-250/350 Super Duty Truck 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: K3 Relay Ground
Ford F-250/350 Super Duty Truck K3 Relay Ground Secure K3 Relay ground wire to a known good chassis ground. – (1) K3 relay ground – (2) A-pillar (right-side) Fig. 11 Heater Control and Fuel Pump Harness Routing CAUTION Secure heater control and fuel pump harnesses away from hot exhaust components and moving vehicle components with cable ties.
Page 11: Heater Preparation And Installation
Ford F-250/350 Super Duty Truck Heater Preparation and Installation ATTENTION Observe torque specifications. Install heater mounting bracket on heater. – (1) Heater mounting bracket – (2) M6 EJOT screw (3 ea.) Torque 10 Nm (88.5 lb-in.) Fig. 15 ATTENTION If the vehicle is not equipped with running boards, install panel nuts provided using the existing holes in the cab.
Page 12: Exhaust Installation
Ford F-250/350 Super Duty Truck Exhaust Installation Secure exhaust tube to heater with 90° exhaust elbow and two clamps. – (1) Exhaust clamp (2 ea.) – (2) Exhaust tube – (3) 90° exhaust elbow Fig. 19 ATTENTION Ensure outlet end of exhaust tube is directed downward and slightly rearward 10 degrees.
Page 13: Integration Into The Coolant System - 6.4 Liter Tt Diesel
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 29, of this manual for a general outline of the coolant circuit...
Page 14: Coolant Hose Connections - 6.4 Liter Tt Diesel
Coolant Hose Connections - 6.4 Liter TT Diesel Cut supplied hoses as shown in Figure 22. Hose A: From engine to coolant pump inlet - Connect the 90° end to the coolant pump at the Webasto heater. Discard Hose B: From Webasto heater outlet to vehicle heater core inlet - Connect the 90°...
Page 15: Integration Into The Coolant System - 6.8 Liter V10 Gasoline
Fig. 25 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. Hose C: Connects Hose B to heater core supply hose. NOTE: Also see the plumbing schematic, page 29, of this manual for a general outline of the coolant circuit arrangement...
Page 16: Coolant Hose Connections - 6.8 Liter V10 Gasoline
Hose A: From engine to coolant pump inlet - Connect the Discard 90° end to the coolant pump at the Webasto heater. Hose B: From Webasto heater outlet to vehicle heater core inlet via hose C - Connect the 90° end to the heater outlet.
Page 17 ATTENTION Clamp vehicle coolant hose with hose clamping pliers prior to removing hose from engine outlet. Route Webasto heater coolant inlet hose (hose going to heater water pump) to engine outlet tube and cut to appropriate length. Open constant tension clamp securing coolant hose to engine outlet tube and slide clamp back on hose.
Page 18: Combustion Air Intake Installation
Ford F-250/350 Super Duty Truck Combustion Air Intake Installation ATTENTION Observe torque specifications. Ensure air intake silencer is pointed downward when installed. The combustion air intake port is located directly above the coolant pump Install combustion air intake tube on heater. –...
Page 19: Integration Into The Fuel System
Ford F-250/350 Super Duty Truck Integration into the Fuel System Fuel Pump Installation The fuel pump is mounted horizontally along the right inside framerail using an existing hole in the frame. See Figure 34. – (1) Fuel pump – (2) P-clamp, M6 nut and bolt –...
Page 20: Fuel Line And Fuel Pump Harness Routing
Ford F-250/350 Super Duty Truck Fuel Line and Fuel Pump Harness Routing CAUTION Secure fuel line and fuel pump harness away from moving vehicle components and hot exhaust. Route fuel line and fuel pump harness along right framerail towards the rear of the vehicle as shown in Figure 37.
Page 21: Standpipe Installation - 6.4 Liter Tt Diesel
Ford F-250/350 Super Duty Truck Standpipe Installation - 6.4 Liter Diesel Remove fuel sending unit according to the vehicle manufacturers servicing instructions. ATTENTION De-burr both sides of hole after drilling. Drill a 8.5 mm (21/64 in.) hole through the top of the fuel sender in the location shown.
Page 22: Standpipe Installation - 6.8 Liter V10 Gasoline
Ford F-250/350 Super Duty Truck Standpipe Installation - 6.8 Liter Gasoline Remove fuel sending unit according to the vehicle manufacturers servicing instructions. ATTENTION De-burr both sides of hole after drilling. Drill a 8.5 mm (21/64 in.) hole through the top of the fuel sender in the location shown.
Page 23 Ford F-250/350 Super Duty Truck Fuel Line Connections and Routing 6.4 Liter Diesel Install fuel sender assembly according to the vehicle manufacturers servicing instructions. Connect fuel line to standpipe with fuel line coupler and two clamps. Refer to Figure 49 or 50. Secure fuel line to existing vehicle fuel lines and install fuel tank.
Page 24: Power Connection
ATTENTION The power wire has to be extended for vehicles equipped with the 6.8 Liter V10 Gasoline engine. Connect red power lead to battery positive terminal. – (1) Webasto power lead – (2) Battery positive terminal Fig. 54 Ground Connection...
Page 25: 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 26: Heater Lockout Reset Procedure
Heater should attempt to start after inserting fuse. 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 27: Electrical Harness Schematic - Part 1
Ford F-250/350 Super Duty Truck BlueHeat Electrical Harness Schematic - Part 1, Heater Control...
Page 28: Electrical Harness Schematic - Part 2
BlueHeat Ford F-250/350 Super Duty Truck Electrical Harness Schematic - Part 2, HVAC Blower Control...
Page 29: Heater Plumbing Schematic - Inline Method
Ford F-250/350 Super Duty Truck BlueHeat Heater Plumbing Schematic - Inline Method...
Page 30 BlueHeat Ford F-250/350 Super Duty Truck NOTES:...
Page 31 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 32 Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org. 02/2007 Rev. 01/2008 P/N 5001336B www.techwebasto.com...

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