Burner, Replacement - Webasto Air Top 3500 Workshop Manual

Air Top 3500/5000

9.2.7 Burner, Replacement

9.2.7.1 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 11 for a burner (19) without
shield. Steps 12 through 16 refer to an installed burner
with shield (18).
5. Loosen (lever off) fastening clamp (20) of burner (19).
6. Push grommet of fuel supply line 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).
11. Remove burner (19).
12. Remove EJOT FDS screws SF (10).
13. 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).
14. Remove oval head screw (9).
15. Withdraw glow plug / flame sensor (11) from burner
with shield (18).
16. Remove burner with shield (18).
17. Perform procedures on components after
disassembly (refer to 9.1.1).
9.2.7.2 Installation
Perform steps 1 through 5 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
(cable in direction of opening for cable grommet) and
secure with oval head screw (9).
2. Tighten oval head screw (9) with 0.8 ± 0.08 Nm.
3. Locate burner (19) for installation and press grommet
of fuel supply line into housing of heat exchanger (14).
4. Secure burner (19) in position using fastening
clamp (20).
5. Route cable of glow plug/flame sensor (11) below
fastening clip on burner tube (12). Bend down
fastening clip as required.
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.
NOTE
NOTE
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 mat (15).
17. Refit housing components / covers.
9.2.8 Burner Tube, Replacement
9.2.8.1 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).
5. Remove burner (see 9.2.7.1).
6. Remove torx screws (17).
7. Withdraw and remove burner tube (12).
8. Remove and discard sealing ring (13).
9. Perform procedures on components after
disassembly (refer to 9.1.1).
9.2.8.2 Installation
1. Place new sealing ring (13, Fig. 902) into groove on
flange of heat exchanger.
2. Locate burner tube (12) for installation and secure
with torx screws (17).
3. Torque tighten screws to 4.0 ± 0.4 Nm.
4. Install burner (see 9.2.7.2).
5. Install combustion and heating air fan (see 9.2.5.2).
6. Install control unit (see 9.2.4.2).
7. Fit insulation collar (15).
8. Assemble housing components / covers.
9 Repair
907