Webasto BlueHeat Installation Instructions Manual
Dodge 2003 ram 2500; dodge 2004 ram 2500;
dodge 2006 ram 2500; dodge 2007 ram 2500;
dodge 2003 ram 3500; dodge 2004 ram 3500;
dodge 2006 ram 3500; dodge 2007 ram 3500
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Also See for BlueHeat:
- Installation instructions manual (29 pages) ,
- Manual (26 pages) ,
- Owner's manual (4 pages)
Related Manuals for Webasto BlueHeat
Summary of Contents for Webasto BlueHeat
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Page 1: Installation Instructions
BlueHeat Coolant Heater Dodge Ram 2500 / 3500 2003 / 2004 - 5.7 Liter Gasoline 2003 / 2006 - 5.9 Liter Diesel 2007 6.7 Liter Diesel Installation Instructions DOC P/N 5000681B KIT P/N 5000498C... -
Page 2: Table Of Contents
Foreword Scope and Purpose These non-binding installation instructions are intended to support authorized Webasto trained distributors, dealers and personnel in the installation of the Thermo Top BlueHeat coolant heaters. These non-binding installation instructions apply to the vehicles listed on the front cover of this installation document unless technical modifications on the vehicle influence the installation, excluding all liability claims. -
Page 3: Heater Installation Site
2500 / 3500 ODGE RELIMINARY NFORMATION Heater Installation Site The Webasto auxiliary coolant heater is to be installed on the right frame rail near the front bumper. Refer to Figures 1 and 2 for location of heater.. Front Fig. 1 Fig. 2... -
Page 4: Installation
24- 18 GA Yellow - Diagnostic Connection 25-18 GA Orange - Supplemental heating option - Not applicable to BlueHeat 26- 10 GA Brown - Optional ground connection for relay K3 when K3 is mounted with relay K1 and K2 (Same function... - Page 5 2500 / 3500 ODGE NSTALLATION Installation – Drill two holes in vehicle bulkhead (1) for mounting the fuse, relay, resistor cluster. Refer to Figure 4. Fig. 4 – Install two relays (3) and resistor (2) on mounting bracket (4) with hardware provided. Refer to Figure 5. –...
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Page 6: Blower Connection
2500 / 3500 NSTALLATION ODGE – Pull main blower control harness (3) and timer harness (1) through grommet (2) in footwell area. Refer to Figure 8. – Route main blower control harness (3) under dash to the blower motor (4). The blower motor (4) is located below the glove box on the passenger side of the vehicle. -
Page 7: Positive Side
(5). Fig. 13 Legend for Figure 18 Webasto Vehicle A From Webasto Heater X1 B 12 VDC Ignition “On” Fuse Tap C HVAC Control Module M HVAC Blower Motor X Cut wire at 50 mm (2 in.) from motor F1 Fuse - Blower Circuit 25 Amp K1 Relay - Ignition “On”... -
Page 8: Timer Installation
2500 / 3500 NSTALLATION ODGE Timer Installation (General Instructions) DO NOT OVER TIGHTEN MOUNTING SCREW! NOTE: Before installing the timer, please confirm the installation site with your customer. – After selecting a site for the timer, temporarily apply the timer mounting template. - Page 9 2500 / 3500 ODGE NSTALLATION Recommended Standpipe Location - 5.9L Diesel (Spacer Required) – Position the fuel sending unit spacer (3) in the slot identified in figure 18. Use the spacer as a template to mark the hole location for standpipe installation. Remove spacer before drilling hole.
- Page 10 2500 / 3500 NSTALLATION ODGE Fuel Standpipe Instructions - 3500 (HEMI) – Bend standpipe (1) 90 degrees as shown in Figure 21. Fig. 21 NOTE: Use the slotted tube molded into the side of the sending unit to secure the standpipe away from the fuel level float.
- Page 11 2500 / 3500 ODGE NSTALLATION Fuel Pump Installation - Diesel – Install fuel pump (5) on vehicle frame with hardware provided in kit. Refer to Figure 25 for mounting location. – Install rubber fuel line adapter (3) on inlet side of fuel pump (5) and secure with clamp (4).
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Page 12: Heater Installation
2500 / 3500 NSTALLATION ODGE – Route the fuel line (1) along fuel pump harness (2) and vehicle lines toward the engine compartment. Refer to Figure 29. Fig. 29 CAUTION Ensure fuel line is secured away from hot exhaust components. –... - Page 13 – Prepare installation site (7) by cutting away the lower section of the right front spalsh shield (6) (if equipped). See Figure 34. Fig. 34 – Refer to Figure 35 for an overview of how the Webasto heater is installed. Fig. 35 –...
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Page 14: Integration Into Coolant System
2500 / 3500 NSTALLATION ODGE – Secure heater support bracket (3) to the frame / bumper mounting bolt with nut (2) provided. Refer to Figure 37. – Tighten nut securing heater support bracket (3) to EJOT stud(1). Fig. 37 Fuel and Electrical Connections at Heater –... - Page 15 – Cut 90 degree bend from the heater core coolant hose (11) coming from the engine as shown in figure 43. – Connect Webasto heater inlet hose (13) to heater core coolant hose (11) using 90 degree copper reducer (14) and two hose clamps (12).
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Page 16: Exhaust System
2500 / 3500 NSTALLATION ODGE Exhaust – Install 90 degree exhaust elbow (5) onto heater (1) and secure with clamp (6). Refer to Figure 45. – Cut exhaust tube (3) to a length of 22.8cm (9 inches). – Connect exhaust tube (3) to 90 degree elbow (5) and secure with clamp (4). -
Page 17: Final Inspection And Initial Start-Up
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 18: Basic Troubleshooting
Heater Lockout Reset Procedure The BlueHeat is designed with a lockout safety feature built in to 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 19 Dealer and End User service facilities. A PC Diagnostic Interface kit for the BlueHeat is available that allows for more thorough testing and troubleshooting of the heater and its components beyond the scope of this installation manual. The diagnostic kit makes it possible to read and remove (reset) stored malfunction codes from the BlueHeat memory.
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Page 20: Wiring Schematics
2500 / 3500 NSTALLATION ODGE Heater Harness Schematic - Heater Control Portion... - Page 21 2500 / 3500 ODGE NSTALLATION Heater Harness Schematic - Blower Control Portion...
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Page 22: Coolant Schematic
2500 / 3500 NSTALLATION ODGE Heater Plumbing Schematic - Inline Method... - Page 24 Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us www.techwebasto.com Org. 10/2002 Rev. 10/2004 P/N 5000681B...
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