Replacement Of Flame Sensor - Webasto Air Top 2000 D Service And Repair Manual

9 Repair

9.2.5 Replacement of Flame Sensor

9.2.5.1 Removal
1. Remove air heater (see 8.7.1.1).
2. Remove control unit (see 8.7.2.1).
3. Remove combustion air fan (see 9.2.4.1).
4. Remove 2 screws (3, Fig. 904) and spoiler (2) for
cable protection.
5. Push out cable grommet (10) towards inside.
6. Carefully bend up locking tab (4) and withdraw flame
sensor (1) from burner insert (5).
7. Remove flame sensor.
8. Perform work on components after disassembly
(see 9.1.1).
9.2.5.2 Installation
CAUTION
Route cable of flame sensor below fuel pipe.
1. Pass flame sensor (1, Fig. 904) below fuel pipe, feed
connector through opening and push in cable grom-
met (10).
2. Feed cable with protection sleeve through locking tab
and insert flame sensor (1) into burner insert (5).
3. Squeeze locking tab (4).
4. Secure burner insert (5) with four screws (3) and fit
spoiler (2) for cable protection.
5. Pull cable of flame sensor tight.
6. Torque all 4 screws (3) to 4 Nm.
7. Mount combustion air fan (see 9.2.4.2).
8. Install control unit (see 8.7.2.2).
9. Install air heater (see 8.7.1.2).
9.2.6 Replacement of Glow Plug
9.2.6.1 Removal
1. Remove air heater (see 8.7.1.1).
2. Remove control unit (see 8.7.2.1).
3. Remove combustion air fan (see 9.2.4.1).
4. Push out cable grommets (9 and 10, Fig. 904)
towards inside.
5. Remove four screws (3) and spoiler (2).
6. Tilt and withdraw burner insert (5) carefully.
Ensure that burner insert (5) has separated from burner
tube (6).
906
NOTE
CAUTION
The glow plug has to be pulled out with utmost care and
must under no circumstances be twisted (danger of
breaking). After a long period of combustion operation
the glow plug may be caked by fuel deposits. In this
case
allow creep oil to react long enough to free glow plug for
withdrawal.
7. Loosen screw (13) and withdraw and remove glow
plug (11) from burner insert.
8. Perform work on components after disassembly (see
9.1.1).
9.2.6.2 Installation
1. Insert new gasket (7, Fig. 904) into heat exchanger
and bring combustion tube (6) in assembly position.
2. Ensure that starting air bore is not clogged. If required
clean with wire (approx. 1 mm ø) (see Detail A).
CAUTION
During glow plug installation observe twist lock (see De-
tail B). That means that the glow has to be inserted so
that the contacts point towards the heat exchanger.
Otherwise there will be the danger of a short circuit.
3. Feed glow plug (11) into burner insert (5) and arrange
cable protective sleeve in slot of burner insert.
CAUTION
When performing the following step ensure that glow
plug is inserted in burner insert fully against stop.
4. Secure glow plug (11) with screw (13). Torque screw
(13) with 0.5 Nm.
5. Locate burner insert (5) in heat exchanger (8) observ-
ing that cable of flame sensor is positioned below
fuel pipe.
6. Feed connectors of glow plug and flame sensor
through openings and push in cable grommets (9
and 10).
CAUTION
When performing the following step ensure that there is
a tight fit between grommet (12) and heat exchanger (8).
7. Secure burner insert (5) using screws (3) and attach
spoiler (2). Torque screws (3) to 4 Nm.
8. Mount combustion air fan (see 9.2.4.2).
9. Install control unit (see 8.7.2.2).
10. Install air heater (see 8.7.1.2).
Air Top 2000