Glow Plug / Flame Sensor, Replacement - Webasto Air Top 3500 Workshop Manual

Air Top 3500/5000

9.2.6 Glow Plug / Flame Sensor, Replacement

9.2.6.1 Removal
1. Remove housing components / covers (see 9.2.1).
2. Remove insulation mat (15, Fig. 902).
3. Remove control unit (see 9.2.4.1).
4. Remove combustion and heating air fan (see 9.2.5.1).
Perform steps 5 through 10 for a burner (19) without
shield. Steps 11 through 14 refer to an installed burner
with shield (18).
5. Loosen (lever off) fastening clamp (20) of burner (19).
6. Push grommet of glow plug / flame sensor (11) out of
housing of heat exchanger (14).
7. If required carefully bend up fastening clip for cable
of glow plug / flame sensor (11) located on burner
tube (12).
8. Withdraw burner (19).
9. Remove oval head screw (9).
10. Withdraw glow plug / flame sensor (11) from burner
(19) and remove.
11. Remove EJOT FDS screws SF (10).
12. Push grommet of glow plug / flame sensor (11) out of
housing of heat exchanger (14) and withdraw burner
with shield (18) from burner tube (12).
13. Remove oval head screw (9).
14. Withdraw glow plug / flame sensor (11) from burner
with shield (18) and remove.
15. Perform procedures on components after
disassembly (refer to 9.1.1).
NOTE
9.2.6.2 Installation
Steps 1 through 5 to be performed for a burner
(19, Fig. 902) without shield. Steps 6 through 13 refer to
an installed burner with shield (18).
1. Insert glow plug / flame sensor (11) into burner (19)
(cable in direction of opening for cable grommet) and
secure with oval head screw (9).
2. Tighten oval head screw with 0.8 ± 0.08 Nm.
3. Locate burner for installation and press grommet of
glow plug / flame sensor (11) into housing of heat
exchanger (14). Bend down fastening clip as required.
4. Route cable of glow plug / flame sensor (11) below
fastening clip and through opening in housing of heat
exchanger (14).
5. Secure burner (19) in position using fastening
clamp (20).
6. Insert glow plug / flame sensor (11) in burner with
shield (18) (cable routed towards opening for
cable grommet in shield) and fasten with oval head
screw (9).
7. Feed cable of glow plug / flame sensor (11) through
opening in shield.
8. Torque oval head screw (9) to 0.8 ± 0.08 Nm.
9. Hold burner with shield (18) upside down, engage
burner tube (12) and rotate to assemble with
combustion tube.
10. Push grommet of fuel supply into housing of heat
exchanger (14).
11. Fasten shield and combustion tube (12) with EJOT
FDS screws SF (10).
12. Torque EJOT FDS screws SF (10) to 2.5 ± 0.25 Nm.
13. Feed cable of glow plug / flame sensor (11) through
heat exchanger and plug grommet.
14. Install combustion and heating air fan (see 9.2.5.2).
15. Install control unit (see 9.2.4.2).
16. Fit insulation collar (15).
17. Refit housing components / covers.
9 Repair
NOTE
905