Dodge Ram 2500 3500 - techwebasto

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

1 PRELIMINARY INFORMATION

BLUEHEAT - DODGE RAM 2500 / 3500

Table of Contents

Foreword

Page

Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . 2

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Heater Installation Site . . . . . . . . . . . . . . . . . . . . . . 3

Vehicle Preparations . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation

Electrical Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Blower Connection . . . . . . . . . . . . . . . . . . . . . . . . . 6

Timer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Integration into Fuel System . . . . . . . . . . . . . . . . . . 8

Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . .12 Integration into Coolant System . . . . . . . . . . . . . . .14 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Power Connection . . . . . . . . . . . . . . . . . . . . . . . . .16 Concluding Work . . . . . . . . . . . . . . . . . . . . . . . . . .16 Final Inspection and Initial Start-up . . . . . . . . . . . . .17 Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .18 Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . .20 Coolant Schematic . . . . . . . . . . . . . . . . . . . . . . . . .22

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. Depending on the version and equipment in the vehicle, changes may be required to the installation work set out in these installation instructions. In any event, however, the directives in the "installation manual" and "operating manual" Thermo Top must be followed. The appropriate engineering conventions must be observed for the installation work.

ATTENTION! All relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary

heating devices must be observed!

CAUTION Location of heater, installation of coolant lines, fuel system and components, wiring and control devices are important for proper operation. Failure to comply with the installation instructions provided may result in

poor operation or damage to heater and vehicle components.

Tools Required

1/4" Drive Ratchet 1/4" Drive 4 inch extension 10 mm six point socket, 1/4" drive 10 mm six point deep well socket, 1/4" drive

3/8" Drive Ratchet 3/8" Drive 12 inch extension 13 mm socket, 3/8" drive 15 mm socket, 3/8" drive 17 mm socket, 3/8" drive

10 mm combination wrench

8 mm nut driver

Phillips #2 screwdriver

2

Combination side-cut/crimping pliers

Hose clamping pliers Hose cutting pliers

Drill 2.5 mm (3/32 in.) drill bit 8 mm (5/16 in.) drill bit 10 mm (25/64 in.) drill bit

Hacksaw Utility Knife Mechanic's wire - 2 feet Hoisting equipment and safety stands Vehicle manufacturer's service reference manual

BLUEHEAT - DODGE RAM 2500 / 3500

1 PRELIMINARY INFORMATION

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..

Fig. 1

Front

Fig. 2

Vehicle Preparations

Heater Kit 1. Verify and identify all contents of kit. Vehicle 1. Verify fuel content in tank.

CAUTION For safety reasons due to weight of fuel and tank, it is recommended there be no more than ? tank or less of fuel present. If fuel quantity is greater than ? of capacity, make provisions to reduce quantity of fuel or

consider removal of pick-up box to gain access to fuel sender location if feasible.

2. Disconnect negative terminal of vehicle battery(s). 3. Remove lower instrument panel fascia (above steering column) to gain access to timer and blower motor harness.

Refer to vehicle manufacturer's instructions for removal. 4. Remove the ash tray and center console fascia. Refer to vehicle manufacturers instructions for removal. 5. Remove right front fender splash shield. 6. Protect vehicle fenders with fender covers and protect seating surfaces against soiling.

3

2 INSTALLATION

BLUEHEAT - DODGE RAM 2500 / 3500

Universal Electrical Harness - Description

Legend for Figure 3 1- Fuse Holder and Fuses 2- Resistor - HVAC blower speed control 3- Relay K1 - HVAC control

2 1 26 25

24

3

4 5

4- Relay K2 - HVAC control

6

5- 18 GA Green - `ON' signal from relay K1 and K2 to

relay K3, Pin 86 (Use when relay K3 is mounted

21

with relay K1 and K2)

6- 18 GA Blue - to Ignition `ON' signal source

7- Main Heater Harness - BlueHeat Coolant Heater

22

23

8- Blower Control Harness - Positive side

9- 10 GA Red - Connects to HVAC control switch

20

7

circuit, positive side, to blower motor

10- 10 GA Black - Connects to HVAC blower motor positive side

11- 18 GA Green - `ON' signal from relay K1 and K2 to

relay K3, pin 86 (Use when relay K3 is mounted

19

near HVAC blower motor - same function as item 5)

12- Blower Control Harness - Negative side

(Harness is wire tied to main harness. Cut wire tie

and separate from main harness before installing)

18

13- 10 GA Blue - Connects to HVAC control switch circuit, negative side, to blower motor

14- 10 GA White - Connects to HVAC blower motor

17

16

negative side

8 9

10

11

12

15- 10 GA Brown - Connects to vehicle ground point when relay K3 is mounted near HVAC blower motor

16- 18 GA Green - Relay K3, pin 86 (Connects to `ON' signal 18 GA green from relay K1 and K2). See item 5 and 11.

17- Relay K3 - HVAC control (Typically mounted near HVAC blower motor)

18- 18 GA Blue & Brown - Fuel Metering Pump Harness

Fig. 13

13

14 15

19- 20 GA Black, Red & Brown - Timer Harness

20- 18 GA Violet - "Vent Mode" for optional remote control

21- Main Power Harness

22- 10 GA Red - Battery Positive

23- 10 GA Brown - Battery Negative or Ground Point

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 as item 15)

4

BLUEHEAT - DODGE RAM 2500 / 3500

Installation

? Drill two holes in vehicle bulkhead (1) for mounting the fuse, relay, resistor cluster. Refer to Figure 4.

2 INSTALLATION

1

Fig. 4

? Install two relays (3) and resistor (2) on mounting bracket (4) with hardware provided. Refer to Figure 5.

? Install mounting bracket (4) on bulkhead (1) with two M6 capscrews and nuts.

? In this application the fuses were mounted behind the mounting bracket (4) using a nylon wire tie.

Harness Routing

Fig. 5

? Route heater control harness (5) to the passenger side of the engine compartment following the vehicle battery cables (6). Route heater control harness (5) down to the heater mounting location along the fan shroud (7). Refer to Figure 6.

? Use the existing harness clips and nylon cable ties to secure heater control harness.

7

Fig. 6

NOTE: The timer and blower control harnesses can be routed through unused bulkhead grommets if available, otherwise perform the following step.

? Cut a ? inch hole in the bulkhead main harness grommet (8). Route timer and blower control harnesses (9) through grommet (8) into the drivers foot-well area. Refer to Figure 7.

FFigig..77

2 4 3

5 6

9 8

5

 ................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download