Step one. Bought the van.
Hello Everybody, First post. I camp a lot in tents but after spending three days straight in a tent in the rain at Dolly Sods I swore I'd make a change. Here it is. Bought it Wednesday. Dro...
Forum Discussion
Webasto heater installation continued:
How the heater appears with the Upper Shell removed.
To remove the Lower Shell look on each side of the heater about the mid point and you will see this small round catch. Pull the side of the Lower Shell away from the catch till it pops out. Do this on both sides then lift the heater from within the Lower Shell.
You'll have to lift the Heater Air Intake from the Lower Shell at the same time.
Put the shell off to the side and place the heater back on the mounting platform. Before preceding I want to point out a few things.
Wrapped around the Heat Exchanger is the Insulation or more appropriately in this case, what's left of it.
The Webasto repair manual name for it is "Insulation" so I'm assuming it's original purpose was to insulate the Heat Exchanger from the plastic of the outer shell. All that's left of mine is a thin metal band and some felt-like material scraps.
On the top of the Control Unit there is a small round electrical component wired into the X9 Connector. This is a 10K ohm thermistor. A thermistor is a type of electrical resistor whose resistance changes with temperature. It's what the heater uses as it's air temperature sensor. If you were to wire up an external temperature sensor, this is where you'd connect it.
Also on top of the Control Unit is the CO2 Adjustment. From the manual: "The CO2 contents of the exhaust is adjusted with the potentiometer on the control circuit board.The air heater is preset by the manufacturer with respect to the combustion and heating air fan fitted. After adjustment by the manufacturer the potentiometer is in center position."
When a heater is changed for high altitude operation this is where the adjustment is made.
Remove the Control Unit next. There are a series of five connectors along one side. From left to right these are the X1 to X5 Connections.
On the Control Unit just above where the connectors are attach is a segmented colored strip. Each color corresponds to the color of the connector wire plugged in below it. Unplug the five connectors.
Remove the two screws on the top of the Control Unit that hold it place.
Lift it off.
A quick word about one of my little helpers. I take a plastic ice cube tray that was no longer used since it had started leaking. Write sequential numbers above each "cube". As I take something apart I place the screws in the tray in the order that I remove them. Helps greatly with reassembly.
Next remove the Combustion Air Fan assembly. Look to the side where the two pairs of wires are underneath this clip. One pair is yellow and the other pair isn't.
Slip the wires out from under the clip.
Next there are five screws to remove but you want to be careful you don't remove the wrong five. In the following picture there are three screw visible. Remove the ones on the right and left but not the one in the middle.
Here's the view on the lower front side. I've already removed the upper right screw and am about to remove the lower screw. Don't remove the screw in the middle.
I was careful in the order that I removed the screws in case one was different but they are all the same.
Very Carefully separate the Combustion Air Fan from the Heat Exchanger. There is a gasket separating the two parts that might be reused if handled carefully.
The heater oval base and Heat Exchanger are cast as a single piece. Since the fuel pump wiring is part of the Combustion Air Fan the wires must be pulled up through the base to completely separate the Combustion Air Fan from the Heat Exchanger.
Set the Combustion Air Fan off to the side.
You can see the gasket stayed attached to the Heat Exchanger.
Very gently pull the gasket away from the Heat Exchanger. No tools needed. Be careful not to bend it.
This one is in good enough shape to use again.
continued -
How the heater appears with the Upper Shell removed.
To remove the Lower Shell look on each side of the heater about the mid point and you will see this small round catch. Pull the side of the Lower Shell away from the catch till it pops out. Do this on both sides then lift the heater from within the Lower Shell.
You'll have to lift the Heater Air Intake from the Lower Shell at the same time.
Put the shell off to the side and place the heater back on the mounting platform. Before preceding I want to point out a few things.
Wrapped around the Heat Exchanger is the Insulation or more appropriately in this case, what's left of it.
The Webasto repair manual name for it is "Insulation" so I'm assuming it's original purpose was to insulate the Heat Exchanger from the plastic of the outer shell. All that's left of mine is a thin metal band and some felt-like material scraps.
On the top of the Control Unit there is a small round electrical component wired into the X9 Connector. This is a 10K ohm thermistor. A thermistor is a type of electrical resistor whose resistance changes with temperature. It's what the heater uses as it's air temperature sensor. If you were to wire up an external temperature sensor, this is where you'd connect it.
Also on top of the Control Unit is the CO2 Adjustment. From the manual: "The CO2 contents of the exhaust is adjusted with the potentiometer on the control circuit board.The air heater is preset by the manufacturer with respect to the combustion and heating air fan fitted. After adjustment by the manufacturer the potentiometer is in center position."
When a heater is changed for high altitude operation this is where the adjustment is made.
Remove the Control Unit next. There are a series of five connectors along one side. From left to right these are the X1 to X5 Connections.
On the Control Unit just above where the connectors are attach is a segmented colored strip. Each color corresponds to the color of the connector wire plugged in below it. Unplug the five connectors.
Remove the two screws on the top of the Control Unit that hold it place.
Lift it off.
A quick word about one of my little helpers. I take a plastic ice cube tray that was no longer used since it had started leaking. Write sequential numbers above each "cube". As I take something apart I place the screws in the tray in the order that I remove them. Helps greatly with reassembly.
Next remove the Combustion Air Fan assembly. Look to the side where the two pairs of wires are underneath this clip. One pair is yellow and the other pair isn't.
Slip the wires out from under the clip.
Next there are five screws to remove but you want to be careful you don't remove the wrong five. In the following picture there are three screw visible. Remove the ones on the right and left but not the one in the middle.
Here's the view on the lower front side. I've already removed the upper right screw and am about to remove the lower screw. Don't remove the screw in the middle.
I was careful in the order that I removed the screws in case one was different but they are all the same.
Very Carefully separate the Combustion Air Fan from the Heat Exchanger. There is a gasket separating the two parts that might be reused if handled carefully.
The heater oval base and Heat Exchanger are cast as a single piece. Since the fuel pump wiring is part of the Combustion Air Fan the wires must be pulled up through the base to completely separate the Combustion Air Fan from the Heat Exchanger.
Set the Combustion Air Fan off to the side.
You can see the gasket stayed attached to the Heat Exchanger.
Very gently pull the gasket away from the Heat Exchanger. No tools needed. Be careful not to bend it.
This one is in good enough shape to use again.
continued -
