Webasto BlueHeat Thermo Top User manual

DOC P/N 5001336B KIT P/N 5001335C Printed in USA Webasto Product N.A., Inc.
BlueHeat Coolant Heater
Thermo Top
Special Tools
– Hose Clamping pliers
– Torque Wrench
Table of Contents
Ford F-250/350 Super Duty
6.4 Liter TT Diesel
6.8 Liter V10 Gasoline
Beginning Model Year: 2008
Special instructions for these models
Part locations may differ slightly dependent on
the vehicle model.
Foreword
Parts List 3
Vehicle Information 3
Scope and Purpose 3
Symbol Identification 4
General References 5
Preparation 5
Heater Installation Site 5
Installation
Electrical - Overview 6
Electrical Harness Installation 7
Timer Installation 7
Fuse Tap Connection - Relay K-1 8
Integration into the Blower System 8
3-Relay HVAC Harness Connections 9
K3 Relay Ground 10
Heater Control and Fuel Pump Harness Routing 10
Heater Preparation and Installation 11
Heater Mounting 11
Exhaust Installation 12
Integration into the Coolant System -
6.4 Liter TT Diesel 13
Coolant Hose Connections -
6.4 Liter TT Diesel 14
Integration into the Coolant System -
6.8 Liter V10 Gasoline 15
Coolant Hose Connections -
6.8 Liter V10 Gasoline 16
Combustion Air Intake Installation 18
Integration into the Fuel System 19
Fuel Pump Installation 19
Fuel Line and Fuel Pump Harness Routing 20
Standpipe Installation - 6.4 Liter TT Diesel 21
Standpipe Installation - 6.8 Liter V10 Gasoline 22
Power Connection 24
Ground Connection 24
Final Inspection, Initial Start-up and Concluding
Work 25
Heater Lockout Reset Procedure 26
Electrical Harness Schematic - Part 1 27
Electrical Harness Schematic - Part 2 28
Heater Plumbing Schematic - Inline Method 29

Warning
• Improper installation or repair of Webasto heating and cooling systems can
cause fire or the leakage of deadly carbon monoxide leading to serious injury
or death.
• Installation and repair of Webasto heating and cooling systems requires spe-
cial Webasto training, technical information, special tools and special equip-
ment.
• NEVER attempt to install or repair a Webasto heating or cooling system unless
you have successfully completed the factory training course and have the
technical skills, technical information, tools and equipment required to prop-
erly complete the necessary procedures.
• ALWAYS carefully follow Webasto installation and repair instructions and
heed all WARNINGS.
• Webasto rejects any liability for problems and damage caused by the system
being installed by untrained personnel or by improper installation.
• Improper installation or installation by untrained personnel voids all warranties
on this product.
If there are any questions regarding the installation or maintenance of this product,
please call technical support at 1-800-555-4518.

3
Ford F-250/350 Super Duty Truck BlueHeat
TM
Parts List
Vehicle Information
Foreword
The installation and service of Webasto Thermo Top series (BlueHeat) heaters requires special expertise and
training. Installations and servicing of Webasto products by untrained, unauthorized personnel and end-users
voids all warranties and releases Webasto Product North America, Inc. and Webasto authorized distributors,
dealers and their personnel from responsibility for damage to Webasto products, any resulting collateral
property damage and personal injury.
Any use, operation, installation, modification or application of the product not described in Webasto manuals,
or subjecting the product to extreme or unusual conditions beyond the limits of specified performance
characteristics is misuse of the product.
Failure to comply with all installation instructions is a misuse of Webasto products. The same applies for repairs
without using genuine Webasto service parts. This will void the coolant heaters “official Marks of Conformity.”
Scope and Purpose
These installation instructions are intended to support Webasto trained and authorized distributors and dealers
in the installation of the Thermo Top series (BlueHeat) Coolant Heaters. These instructions are not intended for
use by untrained or unauthorized personnel.
The directives in the “installation manual” and “operating manual” for the Thermo Top series heater must be
followed. Acknowledged 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.
Quantity Part Part Number
1 Heater Kit - 6.4 L Diesel
or
Heater Kit - 6.8 L Gasoline
5001325A
5000516C
1 Installation Kit 5001335C
Manufacturer Model Year Engine Type
Ford F-250/350 Super Duty Beginning Model
Year: 2008
6.4 Liter Diesel
and
6.8 Liter Gasoline

4
BlueHeat
TM
Ford F-250/350 Super Duty Truck
Symbol Identification
Symbols that define sections in manual
Mechanical Preparation
Electrical
Coolant
G
eneral Symbol Descriptions
Warning
Caution
Flammable or Combustible
Fuel
Exhaust
Combustion Air Intake
Refer to Webasto or Manufacturer Manual
Attention
Line of Sight/Item Location on Vehicle

Ford F-250/350 Super Duty Truck
5
General References
– Bare body parts, for example, around drilled holes, must be treated with anti-corrosive coating.
– Secure hoses, cables and wiring harnesses with cable ties and fit protective hoses around them at chafing
points.
– Fit edge protectors (opened fuel hose) to sharp edges.
Preparation
Heater Kit
– Verify and identify all contents of kit.
Vehicle
– Verify fuel content in tank.
CAUTION
For reasons of safety due to the weight of fuel and the tank, it is recommended that there be no more than 1/4
tank of fuel present. If fuel quantity is greater than 1/4 of capacity, make provisions to reduce quantity of fuel or
consider removal of pick-up box to gain access to fuel sender.
– Disconnect negative terminal of vehicle battery(s).
– Remove Air Cleaner Assembly
– Remove instrument panel cover for timer mounting. Refer to vehicle manufacturers instructions.
– Protect vehicle fenders, panels and interior with covers
Heater Installation Site
Mount the Webasto auxiliary heater under the right side
of the cab, behind the front tire.
– (1) Webasto auxiliary coolant heater (Installed)
– (2) Right-front running board bracket
1
Fig. 1
2
BlueHeat
TM

6
Ford F-250/350 Super Duty Truck
Electrical - Overview
ATTENTION
If not described differently, secure wiring and cables with cable ties to the vehicle’s own wires and cable harnesses.
ATTENTION
Timer control location is a recommendation only. Please consult with the customer before mounting.
HVAC Blower Motor Fuel Metering Pump
(1) Blower Motor (1) Right Framerail
(2) Fuel Pump
Fuse Block/Relays/Resistor Timer Control
(1) Relays K1 & K2 (1) Digital Timer
(2) Fuse Holder
12
1
1
2
1

Ford F-250/350 Super Duty Truck
7
Electrical Harness Installation
ATTENTION
Modify electrical mounting bracket as shown in
Figure 2.
Cut wire tie holding negative-side blower harness (with
relay) from main harness and set aside.
Install resistor and relays on electrical mounting bracket.
– (1) Mounting bracket
– (2) Resistor
– (3) Screw M3x10, Nut M3 (2 ea.)
– (4) Pan head screw 10-32x5/8”, Nut 10-32 (2 ea.)
– (5) Relays K1 and K2
Secure the electrical mounting bracket assembly to the
bulkhead using a self-tapping screw.
– (1) Vehicle bulkhead - left corner
– (2) Electrical mounting bracket assembly
CAUTION
Use care when cutting bulkhead grommet to prevent
damage to vehicle electrical harnesses.
Cut a 12.7 mm (.5 inch) slit in the bulkhead pass-through
grommet.
Route the timer and blower control harnesses into the
interior of the vehicle through the bulkhead grommet.
Timer Installation
CAUTION
Check behind panels for obstructions before drilling
holes.
ATTENTION
Before installing the timer, please confirm the
installation location with the customer.
Affix supplied template to panel. Drill 10 mm (25/64 in.)
and 2.5 mm (3/32 in.) holes where indicated on template.
Figure 5 shows a translated sample of the template
supplied.
3
Fig. 2
4
21
5
Fig. 3
2
1
Fig. 4
IMAGE NOT AVAILABLE
Fig. 5

8
Ford F-250/350 Super Duty Truck
– (1) Timer - recommended location only
Fuse Tap Connection - Relay K-1
CAUTION
Tap into the “fused” output side of the selected fuse.
Locate a fuse (10 to 20 amp) in the fuse / relay center
that is “HOT” when the ignition is in the ON position
only.
Route blue fuse tap wire from relay K-1 to the fuse /relay
center.
– (1) Underhood fuse / relay center
– (2) Fuse tap
ATTENTION
The underhood fuse / relay center cover has to be
modified slightly to close properly after installing the
fuse tap.
Modify cover in locations circled in Figure 8.
– (1) Underhood fuse / relay cover
Integration into the Blower System
Route Blower harness over to blower area.
Mount negative-side blower harness and relay in vicinity
of HVAC blower.
Wire according to schematic in Figure 10.
– (1) Relay K3
– (2) Blower motor connector
– (3) Blower power wire
– (4) Blower ground wire
Fig. 6
1
1
Fig. 7
2
6.8 liter
V 10
Fuse For
Fig. 8
1
1
2
Fig. 9
3
4

Ford F-250/350 Super Duty Truck
9
3-Relay HVAC Harness Connections
NOTE:
It is permissible to cut excess length from
Webasto HVAC wiring harnesses to fit the
application.
Cut motor wires where indicated by “
X
”
– (1) Chassis ground
– (2) Splice green wire to green wire
– (3) Strip and crimp red to controller side
power wire
– (4) Strip and crimp black to motor side power
wire
– (5) Strip and crimp white to motor side
ground wire
– (6) Strip and crimp blue to controller side
ground wire
CAUTION
Check your wiring! Ensure that all connections
have been done in accordance with the wiring
diagram shown (Fig. 10). Sensitive electronic
controls can be damaged if wired incorrectly!
Secure HVAC blower control wiring to vehicle
structures with nylon wire ties. (Image not
available)
NOTE:
Complete heater harness schematics are
included on page 27 and 28 of this manual.
2
1
6
5
4
3
Webasto Vehicle
Fig. 10
YL/GN
YL/GN
PL/PK
PL/PK
K2 Relay - Positive Side of Blower Motor
K3 Relay - Negative Side of Blower Motor
R1 Resistor - Blower Speed Control
30 Battery Positive (Constant Power)
15 Ignition (Switched Power)
31 Battery Negative (Chassis Ground)
Legend for Figure 10
A From Webasto Heater X1
B 12 VDC Ignition ‘On’ Fuse Tap
C HVAC Control Module
M HVAC Blower Motor
XCut wire at 50 mm (2 in.) from motor
F1 Fuse - Blower Circuit 25 Amp.
K1 Relay - Ignition ‘On’ Interrupt

10
Ford F-250/350 Super Duty Truck
K3 Relay Ground
Secure K3 Relay ground wire to a known good chassis
ground.
– (1) K3 relay ground
– (2) A-pillar (right-side)
Heater Control and Fuel Pump Harness
Routing
CAUTION
Secure heater control and fuel pump harnesses away
from hot exhaust components and moving vehicle
components with cable ties.
Route the heater control and fuel pump harnesses under
the engine to the right side of the vehicle.
– (1) Heater control and fuel pump harnesses
– (2) Engine oil pan
Secure the heater control and fuel pump harnesses to the
engine cradle with cable ties. See Figure 13.
– (1) Engine oil pan
– (2) Engine cradle
– (3) Heater control and fuel pump harnesses
Route the heater control and fuel pump harnesses over
the right framerail where shown in Figure 14.
– (1) Heater control and fuel pump harnesses
– (2) Right framerail
ATTENTION
The remainder of the fuel pump harness will be routed
later in this manual.
1
2
Fig. 11
Fig. 12
2
1
Fig. 13
2
13
Fig. 14
21

Ford F-250/350 Super Duty Truck
11
Heater Preparation and Installation
ATTENTION
Observe torque specifications.
Install heater mounting bracket on heater.
– (1) Heater mounting bracket
– (2) M6 EJOT screw (3 ea.) Torque 10 Nm (88.5 lb-in.)
ATTENTION
If the vehicle is not equipped with running boards,
install panel nuts provided using the existing holes in
the cab.
Position the heater in it’s mounting location.
Align the holes in the rear of the mounting bracket with
the panel nuts previously installed or existing hardware
used to secure running boards and mark the front
mounting hole location on the cab.
Set heater aside and drill the front mounting hole.
– (1) Front mounting hole location (5/16 in. hole)
– (2) Cab body (behind front right wheel)
– (3) Panel Nuts
Heater Mounting
ATTENTION
Use existing hardware to secure the heater if the
vehicle is equipped with running boards (See Figure 1).
Connect heater harness to heater (not shown).
Install heater on cab with hardware provided.
– (1) M8 bolt, washer, panel nut (2 ea.)
– (2) Heater/mounting bracket assembly
ATTENTION
Pull the inner fender splash shield back to install the
front mounting hardware.
Install the front mounting hardware.
– (1) Heater/mounting bracket
– (2) M8 bolt, washer, and flange nut
Fig. 15
2
1
Fig. 16
12
3
Fig. 17
1
2
1
Fig. 18
1
2

12
Ford F-250/350 Super Duty Truck
Exhaust Installation
Secure exhaust tube to heater with 90° exhaust elbow
and two clamps.
– (1) Exhaust clamp (2 ea.)
– (2) Exhaust tube
– (3) 90° exhaust elbow
ATTENTION
Ensure outlet end of exhaust tube is directed
downward and slightly rearward 10 degrees.
Secure the exhaust tube using existing holes in body and
p-clamps provided.
– (1) Exhaust tube
– (2) P-clamp, M6 bolt, nut, and washer (3 ea.)
Fig. 19
1
3
2
Fig. 20
2
1

Ford F-250/350 Super Duty Truck
13
Integration into the Coolant System - 6.4 Liter TT Diesel
ATTENTION
Torque hose clamps to 2.0 - 2.5 Nm (18 - 22 lb-in.)
Avoid sharp bends and kinks when installing coolant hoses.
Position hose clamps in such a way to avoid cutting or damaging adjacent components.
ATTENTION
Clamp vehicle coolant hose with hose clamping pliers prior to cutting to prevent coolant spillage.
The coolant heater integration into the vehicle heater circuit is done in an “INLINE” fashion. Refer to Figure 21.
Coolant flow and connection detail:
Hose A: From engine to Webasto coolant pump inlet.
Hose B: From Webasto heater outlet to vehicle heater core inlet.
NOTE:
Also see the plumbing schematic, page 29, of this manual for a general outline of the coolant circuit
arrangement.
Fig. 21

14
Ford F-250/350 Super Duty Truck
Coolant Hose Connections - 6.4 Liter TT Diesel
Cut supplied hoses as shown in Figure 22.
Hose A: From engine to coolant pump inlet - Connect the
90° end to the coolant pump at the Webasto heater.
Hose B: From Webasto heater outlet to vehicle heater
core inlet - Connect the 90° end to the heater outlet.
ATTENTION
Install metal conduit on coolant hoses prior to
installation.
Connect 90° end of hose “A” to Webasto heater coolant
pump.
Connect 90° end of hose “B” to Webasto heater outlet.
Route coolant hoses above the inner fender splash shield
to the engine compartment.
– (A) Webasto heater inlet hose
– (B) Webasto heater outlet hose
– (1) Hose clamp - 2ea.
– (2) Coolant pump
– (3) Metal conduit
ATTENTION
Confirm supply and return hoses to vehicle heater
core before cutting any coolant hoses. Once
confirmed, cut supply hose, leaving sufficient hose
for connections.
Cut the heater core supply hose approximately 3 in. from
the 90° bend in hose. Rotate supply hose toward the
right side of the vehicle. See Figure 24.
Route the Webasto heater outlet hose “B” over to the
heater core supply hose (90° section) and trim to proper
length.
Connect the Webasto heater outlet hose “B” to the
heater core supply hose with coolant adapter and two
hose clamps.
Route the Webasto heater inlet hose “A” to heater core
supply hose (engine side) and trim to proper length.
Connect the Webasto heater inlet hose “A” to the heater
core supply hose with coolant adapter and two hose
clamps.
– (1) Heater core supply hose
– (A) Webasto heater inlet hose, adapter, and two
clamps
– (B) Webasto heater outlet hose, adapter, and two
clamps
Fig. 22
Discard
Discard
A
B
Fig. 23
B
2
3
1
1
A
Fig. 24
1
B
A

Ford F-250/350 Super Duty Truck
15
Integration into the Coolant System - 6.8 Liter V10 Gasoline
ATTENTION
Torque hose clamps to 2.0 - 2.5 Nm (18 - 22 lb-in.)
Avoid sharp bends and kinks when installing coolant hoses.
Position hose clamps in such a way to avoid cutting or damaging adjacent components.
ATTENTION
Clamp vehicle coolant hose with hose clamping pliers prior to removing to prevent coolant spillage.
The coolant heater integration into the vehicle heater circuit is done in an “INLINE” fashion. Refer to Figure 25.
Coolant flow and connection detail:
Hose A: From engine to Webasto coolant pump inlet.
Hose B: From Webasto heater outlet to vehicle heater core inlet.
Hose C: Connects Hose B to heater core supply hose.
NOTE:
Also see the plumbing schematic, page 29, of this manual for a general outline of the coolant circuit arrangement
Fig. 25

16
Ford F-250/350 Super Duty Truck
Coolant Hose Connections - 6.8 Liter V10
Gasoline
Cut supplied hoses as shown in Figure 26.
Hose A: From engine to coolant pump inlet - Connect the
90° end to the coolant pump at the Webasto heater.
Hose B: From Webasto heater outlet to vehicle heater
core inlet via hose C - Connect the 90° end to the heater
outlet.
Hose C: From Webasto heater outlet hose to the coolant
hose removed from the engine coolant outlet tube.
Prepare 180° coolant hose “C” for installation by
installing coolant adapters as shown in Figure 27.
– (C) 180° coolant hose
– (1) Hose clamp - 2ea.
– (2) Coolant adapter - 2ea.
ATTENTION
Install metal conduit on coolant hoses prior to
installation.
Connect 90° end of hose “A” to Webasto heater coolant
pump.
Connect 90° end of hose “B” to Webasto heater outlet.
Route coolant hoses above the inner fender splash shield
to the engine compartment.
– (A) Webasto heater inlet hose
– (B) Webasto heater outlet hose
– (1) Hose clamp - 2ea.
– (2) Coolant pump
– (3) Metal conduit
Fig. 26
A
Discard
Discard
B C
Fig. 27
1
C
2
Fig. 28
A
B
1
1
3
2

Ford F-250/350 Super Duty Truck
17
ATTENTION
Clamp vehicle coolant hose with hose clamping pliers
prior to removing hose from engine outlet.
Route Webasto heater coolant inlet hose (hose going to
heater water pump) to engine outlet tube and cut to
appropriate length.
Open constant tension clamp securing coolant hose to
engine outlet tube and slide clamp back on hose.
– (1) Engine outlet coolant hose
– (2) Constant tension clamp
– (3) Engine outlet tube
Pull vehicle coolant hose off engine outlet tube and install
the Webasto heater inlet hose “A” with clamp.
Route Webasto heater outlet hose “B” to the engine
outlet tube and cut to the appropriate length. See Figure
30.
Install the 180° coolant hose “C” between the webasto
heater outlet hose “B” and the vehicle coolant hose
removed from the engine outlet tube.
– (A) Webasto heater inlet hose
– (B) Webasto heater outlet hose
– (C) 180° Webasto heater hose
– (1) Hose clamp -2ea.
– (2) Engine outlet tube
– (3) Constant tension clamp
– (4) Coolant hose from engine outlet tube
Install plastic protective loom over coolant hose
connections as shown in Figure 31.
Secure coolant hoses with nylon cable tie.
– (1) Plastic protective loom
– (2) Nylon cable tie
Fig. 29
123
Fig. 30
B
A12
C
31 4
Fig. 31
12

18
Ford F-250/350 Super Duty Truck
Combustion Air Intake Installation
ATTENTION
Observe torque specifications.
Ensure air intake silencer is pointed downward when
installed.
The combustion air intake port is located directly above
the coolant pump
Install combustion air intake tube on heater.
– (1) Combustion air tube
– (2) #10 Clamp. Torque 2.0 - 2.5 Nm (18 - 22 lb-in.)
Install the air silencer on the combustion air intake tube.
Route the combustion air intake tube up behind the inner
fender splash shield and secure with cable ties.
Bend the combustion air intake tube so that the silencer
is pointing downward.
Drill a 1/4 in hole through the splash shield near the air
silencer.
Secure the air silencer to the splash shield with the clamp
provided.
– (1) Air intake silencer
– (2) Combustion air intake tube
– (3) Inner fender splash shield
Fig. 32
1
2
Fig. 33
1 2
3

Ford F-250/350 Super Duty Truck
19
Integration into the Fuel System
Fuel Pump Installation
The fuel pump is mounted horizontally along the right
inside framerail using an existing hole in the frame. See
Figure 34.
– (1) Fuel pump
– (2) P-clamp, M6 nut and bolt
– (3) Vehicle framerail (right)
ATTENTION
Ensure the fuel lines are fully seated within the fuel line
couplers and any 90 degree bends are not buckled.
Refer to Figure 35.
Tighten all fuel line clamps to 1.0 - 1.4 Nm (8.8 - 12.4
lb.-in.)
Fuel Line Connection at Heater
ATTENTION
Cover fuel line with loom to protect it form sharp
edges.
Connect fuel line to heater with fuel line coupler and two
clamps.
– (1) Mecanyl fuel line
– (2) Fuel line coupler
– (3) Fuel line clamp (2 ea.)
Fig. 34
1 2
3
Fig. 35
Fig. 36
1 2
3

20
Ford F-250/350 Super Duty Truck
Fuel Line and Fuel Pump Harness Routing
CAUTION
Secure fuel line and fuel pump harness away from
moving vehicle components and hot exhaust.
Route fuel line and fuel pump harness along right
framerail towards the rear of the vehicle as shown in
Figure 37.
– (1) Right framerail
– (2) Mecanyl fuel line (covered with plastic loom) and
fuel pump harness
– (3) Front cab mount
Route fuel line and fuel pump harness along right
framerail towards the rear of the vehicle as shown in
Figure 38.
– (1) Right framerail
– (2) Mecanyl fuel line (covered with plastic loom) and
fuel pump harness
Fuel Line Connection at Fuel Pump
ATTENTION
The outlet end of the fuel pump is quickly identified as
the end with the electrical connector.
Always cut Mecanyl fuel line with a sharp razor knife
or razor edged cutter. DO NOT cut with side cutters,
scissors or similar tools as doing so will cause a
restriction inside the fuel line.
Connect mecanyl fuel line to the outlet side of the fuel
pump with fuel line coupler and two clamps.
– (1) Mecanyl fuel line
– (2) Fuel line clamp (2 ea.)
– (3) Fuel pump electrical connector
– (4) Fuel line coupler
Fuel Pump Harness Connection
Install electrical connector on fuel pump harness per
instructions found in electrical parts bag and connect to
fuel pump.
– (1) Fuel pump harness
– (2) Fuel pump harness connector
– (3) Fuel pump
Fig. 37
23 1
Fig. 38
2
1
Fig. 39
123
4
Fig. 40
123