Webasto BlueHeat User manual

Dodge Ram 2500 / 3500
2003 / 2004 - 5.7 Liter Gasoline
2003 / 2006 - 5.9 Liter Diesel
2007 6.7 Liter Diesel
Installation Instructions
BlueHeat Coolant Heater
DOC P/N 5000681B
KIT P/N 5000498C

1PRELIMINARY INFORMATION BLUEHEAT - DODGE RAM 2500 / 3500
2
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!
Foreword
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
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
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
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.
Page
Table of Contents

Vehicle Preparations
Heater Kit
1. Verify and identify all contents of kit.
Vehicle
1. Verify fuel content in tank.
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.
BLUEHEAT - DODGE RAM 2500 / 3500 1PRELIMINARY INFORMATION
3
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
CAUTION
For safety reasons due to weight of fuel and tank, it is recommended there be no more than ¼ tank or less
of fuel present. If fuel quantity is greater than ¼ 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.

2INSTALLATION BLUEHEAT - DODGE RAM 2500 / 3500
4
Universal Electrical Harness - Description
Legend for Figure 3
1- Fuse Holder and Fuses
2- Resistor - HVAC blower speed control
3- Relay K1 - HVAC control
4- Relay K2 - HVAC control
5- 18 GA Green - ‘ON’ signal from relay K1 and K2 to
relay K3, Pin 86 (Use when relay K3 is mounted
with relay K1 and K2)
6- 18 GA Blue - to Ignition ‘ON’ signal source
7- Main Heater Harness - BlueHeat Coolant Heater
8- Blower Control Harness - Positive side
9- 10 GA Red - Connects to HVAC control switch
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
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)
13- 10 GA Blue - Connects to HVAC control switch
circuit, negative side, to blower motor
14- 10 GA White - Connects to HVAC blower motor
negative side
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
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)
Fig. 1
8
9
10 11
12
13
14
15
1617
18
19
20
26
23
24
25
21
22
1
2
6
5
7
3
4
Fig. 3

BLUEHEAT - DODGE RAM 2500 / 3500 2INSTALLATION
5
1
Fig. 4
Installation
– Drill two holes in vehicle bulkhead (1) for mounting the
fuse, relay, resistor cluster. Refer to Figure 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
– 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.
NOTE: The timer and blower control harnesses can be
routed through unused bulkhead grommets if
available, otherwise perform the following step.
– Cut a ½ 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.
Fig. 5
3
4
2
5
7
Fig. 7
Fig. 6
6
9
8
Fig. 7

2INSTALLATION BLUEHEAT - DODGE RAM 2500 / 3500
6
– 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. Refer to
to Figure 9.
Integration into the Blower System
NOTE: It is permissible to cut excess length from blower
control wiring harnesses.
– Mount blower control K3 relay (6) with auxiliary blower
control harness (5) to vehicle near blower motor (4). Refer to
Figure 9.
– Cut auxiliary blower control harness (5) to desired length.
– Crimp connect green wire (9) from main blower harness (3) to
green wire pigtail (8) at auxiliary blower control harness (5).
Refer to Figure 10.
– Connect brown (ground) wire (7) from auxiliary blower control
harness (5) to a suitable ground point on the vehicle.
– Identify the positive and negative blower control wires (10)
connected to the vehicles blower motor (4). Refer to
Figure 11.
– Cut both vehicle blower control wires at a point about 50 mm
(2 in.) from motor plug and make the connections as
described in the following steps. Also, see Figure 14
Fig. 8 3
1
8
9
3
4
5
6
7
2
10
4
Fig. 9
Fig. 10
Fig. 11
5

BLUEHEAT - DODGE RAM 2500 / 3500 2INSTALLATION
7
Positive blower wire
1. Connect the red wire (3) to the vehicle side of the positive
wire (4). Refer to Figure 12.
2. Connect the black wire (2) to the blower motor side of the
positive wire (1).
Negative blower wire
1. Connect the blue wire (7) to the vehicle side of the negative
blower wire (8). Refer to Figure 13.
2. Connect the white wire (6) to the blower motor side of the
negative wire (5).
Legend for Figure 18
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” 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)
ATTENTION!
Ensure that connections are done correctly. For more detail
of wiring circuits, turn to the back of this manual for
complete wiring schematics.
Fig. 14
7
5
8
32
1
4
6
Fig. 12
Fig. 13
Webasto Vehicle

2INSTALLATION BLUEHEAT - DODGE RAM 2500 / 3500
8
Timer Installation (General Instructions)
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. Refer to Figure 15 for a translated sample
of the template.
– As specified on template, drill the 10 mm (25/64in.) and the
2.5 mm (3/32 in.) holes.
– Remove drilling template.
– Route the timer harness through the 10 mm (25/64 in.) hole.
– Apply foam cushion to back of timer.
– Carefully align timer harness plug with socket on rear of timer
and push into socket until seated.
– Place the timer (1) into position and secure with screw
provided until the timer with foam cushion is firmly seated
against panel. Refer to Figure 16.
– Tighten screw no more than 0.8 Nm (7.0 lb-in.).
DO NOT OVER TIGHTEN!
– Refer to Figure 16 for a completed timer (1) installation
example.
Integration into Fuel System
– Follow the manufacturers service procedure to access and
remove the fuel sender unit from fuel tank.
Recommended Standpipe Location - 5.9L Diesel
(2002-2004)
– Drill a 8.5 mm (21/64 in.) hole (2) through the fuel sender (1)
in the location shown in Figure 17.
– To prevent fuel seepage around standpipe, remove burrs from
both sides of hole (2) after drilling.
Fig. 16: Timer Placement (EXAMPLE ONLY!)
ATTENTION!
Before drilling into any panels, ensure there are no hidden
components behind the panel that may be damaged or
interfere with the timer installation!
DO NOT OVER TIGHTEN MOUNTING SCREW!
1
CAUTION
Full to partially filled fuel tanks are heavy and awkward to
handle. If fuel tank removal is necessary to access fuel
sender, ensure fuel level is near empty.
To prevent accidents or injury to personnel, make sure
tank is well supported prior to removing mounting
hardware.
Fig. 15: Timer Template (NOT TO SCALE!)
1
Fig. 17 2
ATTENTION!
Ensure standpipe location does not interfere with fuel
sender float movement.

BLUEHEAT - DODGE RAM 2500 / 3500 2INSTALLATION
9
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.
– Drill a 8 mm (5/16 in.) hole (2) through the fuel sender (1)
in the location marked.
– To prevent fuel seepage around standpipe, remove burrs from
both sides of hole (2) after drilling.
– Reinstall spacer (3) into slot in fuel sender (1), ensuring the
beveled edge is facing down.
Recommended Standpipe Location - 5.7L Gasoline
(HEMI)
– Drill a 8.5 mm (21/64 in.) hole through the fuel sender (1)
in a location suitable for standpipe installation. See Figure 19.
– To prevent fuel seepage around standpipe (4), remove burrs
from both sides of hole after drilling.
Installing Standpipe with 90 Degree Banjo Fitting
NOTE: Cut standpipe to a length approximately 25 mm
(1 in.) from the bottom of the fuel tank with a 45°
slash-cut. Remove any burrs after cutting tube.
Do not cut standpipe used for the HEMI application
at this time. Preview instructions on page 10 before
proceeding.
– Cut standpipe (4) to length (approximately 13.5 in.) and bend
if necessary to clear any fuel sender components.
– Place one sealing washer (7) on standpipe (4) and insert
standpipe (4) through drilled hole. See Figure 20.
– Place remaining sealing washer(7) on standpipe from
underside. Secure standpipe (4) with lock nut (9). Tighten
lock nut to a torque of 9 ± 0.5 Nm. (80 ± 4.4 lb-in.).
– If necessary, to reposition banjo fitting (6) outlet, loosen
banjo bolt (5) to allow movement. Banjo outlet should run in
the same direction as the other fuel outlet pipes.
– Tighten banjo bolt to a torque of 9 ± 0.5 Nm. (80 ± 4.4 lb-in.)
after repositioning outlet.
Fig. 18
5
6
4
7
8
7
9
Fig. 20
Fig. 19
2
3
1
1
4
Legend for Figure 20
5 Banjo Bolt
6 Banjo Fitting - 90 Degree
4 Standpipe
7 Sealing Washer
8 Fuel Tank or Sender Plate
9 Lock Nut

2INSTALLATION BLUEHEAT - DODGE RAM 2500 / 3500
10
Fuel Standpipe Instructions - 3500 (HEMI)
– Bend standpipe (1) 90 degrees as shown in Figure 21.
NOTE: Use the slotted tube molded into the side of the
sending unit to secure the standpipe away from
the fuel level float.
– Insert standpipe (1) into slotted tube (3) in fuel sender (2) as
shown in Figure 22.
– Fully extend fuel sender (2). Mark standpipe (1) length to
approximately 25 mm (1 in.) from bottom of fuel sender (2).
– Collapse fuel sender (2) and cut off excess standpipe (1) where
marked. The overall length of the standpipe (1), after the
bend, is 34 cm (13.5 in.).
Connecting Fuel Line to Outlet Fitting - All
– Install fuel sender unit (2) according to the vehicle
manufacturers service procedures.
– Align outlet fitting (4) with vehicle fuel lines, as shown in
Figure 23.
– Install rubber fuel line connector (7) on fuel standpipe banjo
outlet nipple and secure with clamp (8).
– Place clamp (6) over rubber connector and insert plastic fuel
line (5) into connector until it bottoms out against nipple.
Secure with clamp (6) as shown in Figure 23.
– Observe Figure 24 for correct fuel line connecting.
– Cover the fuel line (5) with conduit and snap into molded
hold down on the fuel tank. Refer to Figure 23.
– If fuel tank was removed to gain access to sender, install tank
according to manufacturers service procedures.
2
7
5
6
Fig. 23
4
Fig. 21
Fig. 22
Fig. 24
1
3
1
2
8

BLUEHEAT - DODGE RAM 2500 / 3500 2INSTALLATION
11
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).
– Insert fuel line (1) into rubber fuel line adapter (3) until it
bottoms out against nipple and secure with clamp (2).
– Install rubber fuel line adapter (8) on outlet side of fuel
pump (5) and secure with clamp (7). Refer to Figure 26.
– Insert fuel line (10) into rubber fuel line adapter (8) until it
bottoms out against nipple and secure with clamp (9).
– Route fuel pump harness (6) to fuel pump (5) following vehicle
brake/fuel lines and connect to fuel pump (5)
– Cover the fuel line (10) with black conduit. Route the fuel
line (10) with the vehicles fuel lines (11) to the underhood
compartment. Refer to Figure 27.
Fuel Pump Installation - RAM 3500 (HEMI)
– The fuel pump (12) for the HEMI application is located
above the fuel tank on the frame as shown in Figure 28.
– Follow the instructions above for fuel pump installation.
Front
67
58910
Fig. 26
Fig. 28
Front
2
1345
Fig. 25
Front
Front
10
Fig. 27
11
12

2INSTALLATION BLUEHEAT - DODGE RAM 2500 / 3500
12
– Route the fuel line (1) along fuel pump harness (2) and
vehicle lines toward the engine compartment. Refer to
Figure 29.
– Use nylon wire ties to secure fuel line (1) and fuel pump
harness (2) to frame rail. Refer to Figure 30.
– Route the fuel line (1) along heater control harness (3),
across radiator, to the heater mounting location.
Refer to Figure 31.
– Secure fuel line (1) to the heater control harness (3) using
nylon wire ties.
Heater Installation
– Install EJOT stud (7) with M6 washer before installing heater
mounting bracket (5) on heater. See Figures 32 and 35.
– Install heater mounting bracket (5) on heater with two EJOT
screws (4).
– Install heater support bracket (6) on EJOT stud (7) with nut
provided. Do not tighten nut until heater is installed on frame.
3
1
Fig. 31
CAUTION
Ensure fuel line is secured away from hot exhaust
components.
Front
Fig. 30
Fig. 29
1
2
12
ATTENTION!
Some preassembly of the heater is necessary before
installing. The next steps will detail the installation of the
mounting bracket and the combustion air intake tube.
4
Fig. 32
5
7
6

BLUEHEAT - DODGE RAM 2500 / 3500 2INSTALLATION
13
– Remove knock out from top of heater (5) and install the
combustion air silencer clamp (3). Refer to Figure 33.
– Install combustion air intake tube (2) on heater and secure
with clamp (1).
– Thread combustion air silencer (4) into combustion air tube
(2).
– Secure combustion air silencer (4) to top of heater (5) with
previously installed clamp (3).
– Remove right front wheel well splash shield to gain access to
installation site (7).
– Prepare installation site (7) by cutting away the lower section
of the right front spalsh shield (6) (if equipped). See Figure 34.
– Refer to Figure 35 for an overview of how the Webasto heater
is installed.
– Install the heater mounting bracket (8) on vehicle frame rail
(9) with two bolts (12), spacers (11), rear strap, and two
nuts (10). Refer to Figures 35 and 36.
Fig. 34
10
12
Fig. 36
9
8
11
Fig. 35
2
3
4
5
1
Fig. 33
6
7

2INSTALLATION BLUEHEAT - DODGE RAM 2500 / 3500
14
– 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).
Fuel and Electrical Connections at Heater
– Connect heater control harness (4) to the heater. Refer to
Figure 38.
– Pre-assemble rubber fuel line adapter (6) with two clamps.
– Install rubber fuel line adapter (6) on heater and secure
with clamp (7).
– Insert fuel line (8) into rubber adapter (6) until it bottoms out
against the fuel inlet nipple and tighten clamp (5).
Integration into Coolant System - Diesel
– Cut the two formed coolant hoses found in kit to 1.54m
(5 foot) sections. Cut the 180 degree end to 90 degrees on
both hoses.
– Cover both hoses with black conduit before installing.
– Connect 90 degree end of heater inlet hose (11) and heater
outlet hose (9) to heater and tighten hose clamps (10). See
Figure 39.
– Route heater coolant hoses (9) and (11) as shown in Figure 40.
– Secure coolant hoses (9) and (11) using nylon cable ties.
Fig. 37
1
3
2
Fig. 38
CAUTION!
Ensure coolant lines are secured away from all suspension
parts and heat sources!
10
Fig. 39
11
9
Fig. 40
5
87
4
6
9
11 10

BLUEHEAT - DODGE RAM 2500 / 3500 2INSTALLATION
15
– To prevent coolant loss, clamp off coolant hose (1) going to
heater core. See Figure 41.
– Cut vehicle coolant hose (1) coming from engine block (2) in
two places.
– Connect heater inlet hose (3) to coolant hose (1) from engine
block with coupler (5) and two hose clamps (4). See Figure 42.
– Connect heater outlet hose (8) to heater core inlet hose with
90 degree coupler (6) and two hose clamps (7).
Integration into Coolant System - HEMI
– Cut the two formed coolant hoses found in kit to 1.54m
(5 foot) sections. Cut the 180 degree end to 90 degrees on
both hoses.
– Cover both hoses with black conduit before installing.
– Route Webasto heater coolant hoses (13) and (15) along
passenger inner fender well. Refer to Figure 43.
– 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).
– Disconnect OEM heater core coolant hose at connection prior
to the heater core. Discard OEM section of hose, adapter, and
constant pressure clamp.
– Connect Webasto heater coolant outlet hose (15) to heater
core coolant hose (9) using adapter/reducer and two hose
clamps (10). Refer to Figure 43.
Coolant Line Connections at Heater
– Connect coolant inlet hose (13) from engine block to the
Webasto heater circulation pump (17) and tighten clamp (18).
Refer to Figure 44.
– Connect coolant outlet hose (15) from heater core to coolant
outlet on the Webasto heater and tighten clamp (16).
15
13
ATTENTION!
Torque all hose clamps to 1.7 Nm (15 lb-in.).
Fig. 44
17
2
CUT
Fig. 41
ATTENTION!
Removal of the air cleaner assembly will provide greater
access to the inner fender well area.
ATTENTION!
Torque all hose clamps to 1.7 Nm (15 lb-in.).
13
10
Fig. 43
11
12
14
15
9
1
31
68
5
7
4
Fig. 42
16
18

2INSTALLATION BLUEHEAT - DODGE RAM 2500 / 3500
16
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).
– Secure exhaust tube (3) to heater mounting bracket with
clamp (2).
– Bend exhaust tube (3) 90 degrees so it faces to the rear of the
vehicle and down.
Fuse Tap Connection - Relay K1
– Route the blue fuse tap wire (9) to fuse panel (7) as shown in
Figure 46.
– With a test light, find an “Ignition ON” power source. Test
light must be off when ignition key is in the OFF position.
– Using the supplied fuse tap connector, tap into the “fused”
side of the selected fuse (8) as shown in Figure 46.
Power Connection
– Connect red power lead (10) to existing stud (11) in front of
fuse block (7) as shown in Figure 47.
Concluding Work
– Install all vehicle parts, panels and components removed
during heater installation.
– Check that all hose lines, hose clamps and pipe clips and all
electrical connections are secure.
– Secure all loose lines and cables with nylon cable ties
– Spray the heater components and electrical connections with
an anti-corrosive wax coating.
– Turn to “Final Inspection” and “Initial Start-up.”
Fig. 45
Fig. 46
Fig. 47
5
411
1
6
42
9
8
7
11
10 7
3

BLUEHEAT - DODGE RAM 2500 / 3500 2INSTALLATION
17
Final Inspection and Initial Start-up
Final Inspection
Inspect installation for:
• loose fasteners.
• exhaust system routing and clamp tightness.
• combustion air intake tube routing and clamp tightness.
• loose coolant line clamps.
• pinched coolant lines.
• routing of coolant lines and coolant lines securely tied and protected against chaffing and related damage.
• loose fuel line clamps.
• routing of fuel lines and fuel lines securely tied and protected against chaffing and related damage.
• loose wiring connections and battery connections.
• routing of wiring harness and wiring harness securely tied and protected against chaffing and related damage.
• check operation of vehicle heater fan with Webasto heater OFF.
Initial Start-up
1. Top off cooling system with coolant per engine/vehicle manufacturers recommendations.
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:
• hose connections for leaks.
• coolant level in expansion tank. Add coolant as needed.
4. Switch off the engine.
ATTENTION!
Coolant temperature must be below 30 °C (86 °F) before heater will attempt to start.
ATTENTION!
More than one start-up attempt of the heater may be required to purge air from fuel system before heater
will start. Cycle heater Off and On after each failed start attempt until heater starts successfully. No further
start attempts are possible until the control unit lockout condition is cleared.
ATTENTION!
Engine coolant temperature gauge may read lower than actual Webasto heater output temperature. This is
due to the location of the temperature gauge sensor on engine.
5. Switch on the Webasto heater by means of the instant heat button on timer and check:
• timer panel and instant heat indicator illuminates.
• circulating pump in operation.
• initiation of start-up sequence.
• successful start-up and operation.
6. Allow heater to run for 20 minutes or until coolant is heated to temperature. Re-tighten all hose clamps.

2INSTALLATION BLUEHEAT - DODGE RAM 2500 / 3500
18
General Information
This section describes troubleshooting procedures for the BlueHeat coolant heater within the scope of installation.
Troubleshooting is normally limited to the isolation of defective components and provides information on defective wiring
and connections.
Should the heater not function after completing the installation and initial start-up instructions, refer to the following
troubleshooting instructions and information to isolate and remedy the cause for malfunction.
In the event you are unable to remedy a malfunction after following these troubleshooting instructions or for
unanticipated malfunctions beyond what is covered in this troubleshooting section, please contact one of our Webasto
Technical Assistance Representatives for further instructions.
In the USA, call [phone]
In Canada, call [phone]
CAUTION
Troubleshooting requires comprehensive knowledge about structure and theory of operation of the heater
components and may only be performed by Webasto trained and certified, professionals.
Before troubleshooting, check for and eliminate the following probable causes for trouble:
• power supply to heater is less than 10.5 volts at main power connections (charge batteries and perform load test).
• blown fuses.
• corrosion on battery terminals for heater, electrical wiring, connections and fuses.
• loose contacts or connectors, wrong crimping on connectors.
• ensure heater and components have been correctly installed following all pertaining installation instructions.
• shut down initiated by temperature limiter.
• heater control unit locked out. Refer to “Heater Lockout Reset Procedure.”
ATTENTION!
After correction of a malfunction, a functional test has to be performed with heater installed on the vehicle.
Basic Troubleshooting
3.2 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.
Before troubleshooting the heater, ensure heater is not in the “Lockout” mode by performing the following reset
procedure:
1. Ensure timer or switch is in the off position. Turn timer or switch to the on position. Remove main fuse F2 (20 Amp),
Reinsert after 5 seconds.
2. Cycle timer or switch off and then back on once more. Remove fuse F2 once again and reinsert after 5 seconds.
Heater should attempt to start in 10 seconds after inserting fuse.
ATTENTION!
Coolant must be below 60 °C (140 °F) before heater will attempt to start.

BLUEHEAT - DODGE RAM 2500 / 3500 2INSTALLATION
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CAUTION
Diagnostics equipment is intended for use by Webasto trained personnel at authorized Webasto Distributor,
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.
The PC Diagnostic Interface Kit comes complete with connecting hardware, software and instructions for use with any
IBM/PC compatible computer. Also available are several interface connectors for use with Webasto heaters equipped with
internal diagnostic capabilities such as the BlueHeat.
In addition to working with stored malfunction codes, the PC Diagnostics Interface Kit allows you to perform several
other functions such as reading values while the heater is in operation or testing individual components. Printing out
malfunction codes is also available (User supplied printer required).
For further capabilities and instructions for use with the BlueHeat heater, see the instruction manual supplied with the PC
Diagnostics Interface Kit.
Order PC Diagnostics Interface Kit under part number 92542F. Kit does not include required adapter for the BlueHeat
and must be included in your order. Order adapter under part number 92566A.
PC Diagnostics Interface Kit
General Malfunction Symptoms
The following table lists possible malfunction symptoms.
Malfunction Symptom
Coolant heater
switches off
automatically
(Fault lockout)
Heater expels black
fumes from exhaust
Probable Cause
No combustion after start
or automatic repeat start
Flame extinguishes during
operation
Heater overheats
Vehicle electrical system
voltage too low
Combustion air and/or
exhaust ducting blocked
Remedy
Switch off heater momentarily and switch on once again
Switch off heater momentarily and switch on once again
Check coolant lines for obstructions, closed valves and kinks.
Check coolant level. Allow heater to cool down, reset overheat
limiter, switch off heater momentarily and switch on once again
Charge battery
Switch off heater momentarily and switch on once again
Check combustion and exhaust ducting for obstructions
Table 1: General Malfunction Symptoms

2INSTALLATION BLUEHEAT - DODGE RAM 2500 / 3500
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Heater Harness Schematic - Heater Control Portion