Webasto BlueHeat Thermo Top User manual

DOC P/N 5001274A KIT P/N 5001273A Printed in USA Webasto Product N.A., Inc.
BlueHeat Coolant Heater
Thermo Top
Legend
1 Fuse Holder, Relays and Resistor Assembly
2TimerControl
3BlueHeat Coolant Heater, Exhaust Tube, and Combustion Air Intake Silencer
4FuelPump
Special Tools
– Hose Clamping pliers
– Torque Wrench
Table of Contents
124 3
GMC Sierra 2500 HD
GMC Sierra 3500 HD
6.6 Liter Duramax Diesel
Beginning Model Year: 2000
Chevrolet Silverado 2500 HD
Chevrolet Silverado 3500 HD
6.6 Liter Duramax Diesel
Beginning Model Year: 2000
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 7
Timer Installation 7
Fuse Tap Connection - Relay K-1 8
Integration into the Blower System 8
3-Relay HVAC Harness Connections 9
Heater Preparation 11
Heater Installation Site Preparation 12
Heater Installation (Underbody Mount) 13
Exhaust Installation 13
Combustion Air Intake Installation 13
Integration into the Coolant System 14
Integration into the Fuel System 16
Fuel Pump Installation 16
Fuel Line Routing 16
Standpipe Installation - 2000 Through 2003 18
Standpipe Installation - 2004/2006 Model Year 20
Fuel Line Routing from Sender to Pump 22
Power Connection 23
Final Inspection, Initial Start-up and Concluding
Work 24
Heater Lockout Reset Procedure 25
Electrical Harness Schematic - Part 1 26
Electrical Harness Schematic - Part 2 27
Heater Plumbing Schematic - Inline Method 28

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
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD 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 5000515C
1 Installation Kit 5001273A
Manufacturer Model Year Engine Type
GMC
GMC
Chevrolet
Chevrolet
Sierra 2500 HD
Sierra 3500 HD
Silverado 2500 HD
Silverado 3500 HD
Beginning Model
Year: 2000
6.6 Liter
6.6 Liter
6.6 Liter
6.6 Liter

4
BlueHeat
TM
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
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

GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
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 location if feasible.
– Disconnect negative terminal of vehicle battery(s).
– Remove air cleaner, air cleaner housing and air cleaner mounting tray. Refer to vehicle manufacturers
instructions.
– Remove instrument panel fascia for timer mounting. Refer to vehicle manufacturers instructions for fascia
removal.
– Protect vehicle fenders, panels and interior with covers
Heater Installation Site
Mount the Webasto auxiliary heater on the left framerail
just below the drivers compartment.
– (1) Webasto Auxiliary Coolant Heater (Installed)
1
Fig. 1
BlueHeat
TM

6
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
Electrical - Overview
ATTENTION
The routing of cables and wires are done in accordance to the general valid rules of engineering. If not described
differently, securing of wiring and cables is done 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 Timer Control
(1) Blower relay K3 (1) Timer
Fuse Block/Relays/Resistor Fuel Metering Pump
(1) Mounting Bracket (1) Pump
(2) Fuse Holder (2) Connector
(3) Relays K1 & K2 (back of bracket) (3) Mount Strap
11
1
2
3
12
3

GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
7
Electrical Harness
ATTENTION
Cut wire tie holding negative-side blower harness (with
relay) from main harness and set aside.
To attach fuse holder to bracket, a 6.0 mm (1/4 in.) can
be drilled through the bracket. Attach fuse holder with
plastic anchor included. Assemble as shown.
– (1) Mounting Bracket (2 required)
– (2) Screw M3x10, Nut M3
– (3) Pan Head Screw 10-32x5/8”, Nut 10-32
Secure the electrical mounting bracket assembly to the
left corner of the bulkhead using an existing stud and nut
provided in kit.
– (1) Vehicle bulkhead - left corner
– (2) Electrical mounting bracket assembly
– (3) Existing vehicle stud and nut
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.
– (1) Vehicle bulkhead
– (2) 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.
2
Fig. 2
2
1
1
3
3
Fig. 3
3
2
1
Fig. 4
12
Fig. 5

8
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
ATTENTION
Before installing the timer, please confirm the
installation location with the customer.
– (1) Timer - Sample location only
Fuse Tap Connection - Relay K-1
Locate a fuse (15 to 20 amp) in the underhood fuse /
relay center that is “HOT” when the ignition is in the ON
position only.
Route blue fuse tap wire from relay K-1, up into the
under hood fuse panel.
– (1) Fuse tap wire
– (2) Fuse tap
CAUTION
Tap into the “fused” output side of the selected fuse.
– (1) Fuse tap - close up
Integration into the Blower System
Remove panel to access blower area.
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) Positive-side blower integration harness
– (2) Ground point (see item 1, Figure 10)
– (3) Relay K-3 of negative-side harness
– (4) HVAC blower motor
Fig. 6
1
1
2
Fig. 7
Fig. 8
1
1
2
3
4Fig. 9

GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
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 violet
wire
– (4) Strip and crimp black to motor side violet
wire
– (5) Strip and crimp white to motor side black
wire
– (6) Strip and crimp blue to controller side
black 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.
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
K2 Relay - Positive Side of Blower Motor Circuit
K3 Relay - Negative Side of Blower Motor Circuit
R1 Resistor - Blower Speed Control
30 Battery Positive (Constant Power)
15 Ignition (Switched Power)
31 Battery Negative (Chassis Ground)
2
1
6
5
4
3
Webasto Vehicle
Fig. 10
VIOLET
VIOLET
BLACK
BLACK

10
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
Heater Control Harness Routing
CAUTION
Secure heater control harness away from hot exhaust
components and moving vehicle components with
cable ties.
Route heater control harness from the engine
compartment to the left framerail. Keep heater harness
away from the exhaust system and the steering shaft.
– (1) Heater control harness
– (2) Brake fluid reservoir
.
Bundle excess heater harness and secure to left framerail
with cable ties.
– (1) Heater control harness
– (2) Left framerail
2
1
Fig. 11
1
Fig. 12
2

GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
11
Heater Preparation
ATTENTION
Before installing the heater on the bracket look to see if
the bracket has a raised area around the lower heater
mounting hole. If the bracket is flat, position two spacer
washers between the mounting bracket and the heater
before installing the lower EJOT screw.
– (1) Spacer washers
– (2) Lower mounting hole
ATTENTION
Observe torque specifications.
Install the heater on the mounting bracket as shown in
Figure 14.
– (1) M6 EJOT screw x3. Torque 10 Nm (88.5 lb-in.)
– (2) Heater mounting bracket
Cut supplied hoses as shown in Figure 15.
Hose A: From engine to coolant pump inlet =175 cm (69
inches).
Hose B: From Webasto heater outlet to vehicle heater
core inlet = 185 cm (73 inches).
– (A) Heater inlet (supply) hose with 90 degree turn
– (B) Heater outlet (return) hose
Fig. 13
2
1
Fig. 14
1
2
Fig. 15
AB
Fig. 16
A
B

12
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
ATTENTION
Observe torque specifications.
Connect coolant hoses and fuel line coupler to heater as
shown in Figure 17.
– (1) Heater inlet “A” hose with 90 degree turn
– (2) Heater outlet “B” hose
– (3) Fuel line coupler
– (4) Hose clamp - Torque 1.0 - 1.4 Nm (8.8 - 12.4 lb-
in.)
– (5) Hose clamp - Torque 2.0 - 2.5 Nm (18 - 22 lb-in.)
Install exhaust tube on heater with 90° elbow.
– (1) Exhaust tube
– (2) Exhaust clamp x2. - Torque 5 - 5.5 Nm (44 - 49 lb-
in.)
– (3) Exhaust elbow
Heater Installation Site Preparation
ATTENTION
Pull harness clip from existing hole in framerail. This
hole will be used to mount the heater. Secure the
harness to vehicle with cable ties after mounting the
heater.
– (1) Existing holes in left framerail
– (2) Vehicle harness clip
Connect the heater harness to the heater before
installing the heater on the framerail.
– (1) Heater harness
Fig. 17
1
2
3
45
3
Fig. 18
1 2 2
2
Fig. 19
1
1
Fig. 20
1
Fig. 20

GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
13
Heater Installation
Mount the heater and mounting bracket assembly on the
left framerail with 3 screws provided.
– (1) Heater and mounting bracket assembly
– (2) Left framerail
Exhaust Installation
ATTENTION
Ensure outlet end of exhaust tube is directed downward
and slightly rearward 10 degrees.
Secure the exhaust tube using an existing hole in the left
framerail and p-clamp provided.
– (1) Left framerail
– (2) P-clamp, M6 bolt and nut
– (3) Exhaust tube
Combustion Air Intake Installation
ATTENTION
Observe torque specifications.
Attach combustion air intake tube with silencer to heater.
The combustion air intake port is located directly above
the coolant pump
– (1) #10 Clamp. Torque 2.0 - 2.5 Nm (18 - 22 lb-in.)
– (2) Combustion air tube
Route the combustion air intake tube into the left inner
fender area.
Bend the combustion air intake down so that the silencer
is pointing downward and secure to vehicle using cable
ties.
– (1) Air intake silencer
– (2) Left inner fender area
– (3) Combustion air intake tube
Fig. 21Fig. 21
2
1
Fig. 22
1 2 3
Fig. 23
12
Fig. 24
12
3

14
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
Integration into the Coolant System
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 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.
NOTE:
Also see the plumbing schematic, page 31, of this manual for a general outline of the coolant circuit
arrangement.
Fig. 25

GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
15
Coolant Hose Routing
Install a p-clip on the bulkhead using an existing stud and
pushnut provided. The p-clip will be used to secure the
heater coolant hoses to the bulkhead.
– (1) Vehicle bulkhead
– (2) P-clip and pushnut
CAUTION
Avoid sharp bends and kinks when installing coolant
hoses. Keep coolant hoses away from vehicle exhaust
system and moving components.
Route the heater coolant hoses from under the vehicle to
the engine compartment. Continue routing the coolant
hoses toward the heater core, along the bulkhead, as
shown in Figure 27.
Secure the coolant hoses with cable ties to existing
vehicle components and to the p-clip installed previously.
– (1) Cable tie
– (2) Vehicle bulkhead
– (3) Heater coolant hoses
ATTENTION
Confirm supply and return lines to vehicle heater core
before cutting any coolant lines. Once confirmed, cut
supply hose at point close to heater core leaving
sufficient hose for connections.
Use hose clamping pliers to prevent coolant loss.
(1) Heater core supply hose
ATTENTION
Position hose clamps in such a way to avoid cutting or
damaging adjacent components.
Torque hose clamps to 2.0 - 2.5 Nm (18 - 22 lb-in.).
Connect heater hoses coming from the Webasto heater
to heater hose selected in the previous step using the 90°
brass coolant adapters provided.
– (1) Webasto coolant hose returning from heater outlet
to vehicle heater core inlet (hose “B”)
– (2) Webasto coolant hose leading from engine to heater
circulation pump inlet (hose “A”)
– (3) Heater core supply hose
Fig. 26
12
Fig. 27
12
3
Fig. 28
1
Fig. 29
1
2
3

16
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
Integration into the Fuel System
Fuel Pump Installation
The fuel pump is mounted horizontally along the left
inside framerail, ahead of the fuel cooler, using an
existing hole in the frame. See Figures 30 and 32.
– (1) P-clip
– (2) Vehicle framerail
– (3) M6 Fender washer
– (4) Capscrew
– (5) M6 flanged nut
ATTENTION
Ensure the fuel lines are fully seated within the fuel line
couplers and any 90 degree bends are not buckled.
Refer to Figure 31.
Tighten all fuel line clamps to 1.0 - 1.4 Nm (8.8 - 12.4
lb.-in.)
Fuel Line Routing - Fuel Pump to Heater
Connect mecanyl fuel line to the outlet side of the fuel
pump with fuel line coupler.
– (1) Fuel pump - installed
– (2) Fuel line clamp
– (3) Mecanyl fuel line
– (4) Fuel line coupler
Route the fuel line from the fuel pump along the left
frame rail to heater mounting location. Use the existing
vehicle fuel line clips to secure the heater fuel line to the
vehicle.
– (1) Existing vehicle fuel line clip
– (2) Mecanyl fuel line
– (3) Left framerail
– (4) Webasto heater location
2
1
Fig. 30
5
34
Fig. 31
Fig. 32
2 3
4
1
Fig. 33
34 2
1

GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
17
Continue routing the mecanyl fuel line toward the heater.
Use existing vehicle clips and cable ties to secure the fuel
line to the vehicle.
– (1) Mecanyl fuel line (heater)
– (2) Existing fuel line clip
– (3) Fuel line clamp - Torque 1.0 - 1.4 Nm (8.8 - 12.4 lb-
in.)
ATTENTION
Always cut Mecanyl fuel line with a sharp razor knife or
razor edged cutter. Using side cutters, scissors or similar
tools will cause a restriction inside the fuel line
Cut fuel line to length and connect to the fuel line
coupler previously installed.
– (1) Mecanyl fuel line (heater)
– (2) Fuel line coupler
– (3) Fuel line clamp - Torque 1.0 - 1.4 Nm (8.8 - 12.4 lb-
in.)
Fuel Pump Harness Routing
Route the fuel pump harness along side the heater
harness from the engine compartment to the left
framerail.
Route the fuel pump harness down the left framerail to
the fuel pump mounting location following the heater
fuel line. Secure the fuel pump harness to the vehicle
with cable ties.
– (1) Mecanyl fuel line (heater)
– (2) Existing vehicle fuel line clip
– (3) Nylon cable tie
– (4) Electrical harness - fuel pump
Assemble electrical harness connector and connect
harness to pump.
– (1) Heater fuel pump
– (2) Fuel pump electrical harness connector
– (3) Fuel pump electrical harness
Fig. 34
12
1
3
2
Fig. 35
123
4Fig. 36
Fig. 37
231

18
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
Standpipe Installation - 2000 Through 2003 Model Years
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 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 location if feasible.
ATTENTION
Using an appropriate jack and safety stands, lower the
fuel tank and remove the fuel sender unit according to
the vehicle manufacturers servicing instructions.
– (1) Drill hole 8.0 mm (5/16 in.)
ATTENTION
De-burr both sides of hole after drilling.
Cut standpipe to length. The standpipe tube should
terminate approximately 38 mm (1.5 in.) off bottom of
tank when installed.
Bend standpipe as shown.
ATTENTION
Ensure standpipe does not interfere with the float arm
assembly.
Install standpipe, see inset image for item sequence.
– (2) Fuel sender unit
– (3) Standpipe
– (4) Nylon cable tie
1
Fig. 38
2
3
4
Fig. 39
1
2
3
4
5
6
7
Legend for Inset Image
1 Banjo Bolt - Torque 8.5-9.5 Nm (75-84 lb-in.)
2 Banjo Fitting
3 Standpipe
4 Upper Sealing Washer (Black)
5 Fuel Tank
6 Lower Sealing Washer (Brass)
7 Lock Nut - Torque 8.5-9.5 Nm (75-84 lb-in.)

GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
19
– (1) M8 locking nut
Torque to 8.5-9.5 Nm (75-84 lb-in.)
– (2) Holding fixture (not required)
Re-install fuel sender assembly according to the vehicle
manufacturers servicing instructions.
Connect fuel line to fuel sender. Route fuel line forward
along existing vehicle fuel lines. Install fuel tank
according to vehicle manufacturers servicing instructions.
– (1)Fuel standpipe
– (2) Fuel line clamps
Torque 1.0-1.4 Nm (8.8-12.4 lb-in.)
– (3) Fuel line coupler
– (4) Mecanyl fuel line
Route Mecanyl fuel line along existing vehicle fuel lines as
shown. Secure fuel line to existing vehicle fuel lines with
nylon cable ties as shown.
– (1) Mecanyl fuel line
– (2) Nylon cable tie
– (3) Existing vehicle fuel lines
Proceed to page 22 for fuel line routing and connection to fuel pump beginning at Figure 52.
1
2
Fig. 40
12324
Fig. 41
Fig. 42
12
3

20
GMC Sierra / Chevrolet Silverado 2500 HD & 3500 HD
Standpipe Installation - 2004 - 2006 Model Year
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 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 location if feasible.
ATTENTION
Using an appropriate jack and safety stands, lower the fuel tank and remove the fuel sender unit according to
the vehicle manufacturers servicing instructions.
A drilling template is provided on last page of this
manual. Carefully cut out the template and place on
sender unit as shown.
Drill a 1/8 in. pilot hole through the sender where
indicated. The pilot hole must be centered within the
surrounding plastic material when viewed from
underside. See Figure 45 before drilling.
– (1) Drilling template
– (1) Enlarge hole to 8.0 mm (5/16 in.)
ATTENTION
De-burr both sides of hole after drilling.
– (1) Hole viewed from underside
ATTENTION
Note that hole is centered within the surrounding
plastic material.
1
Fig. 43
1
Fig. 44
Fig. 45
1