BlueHeat AirTop 2000 Heater

Air Heater Installation Manual

Special Tools

Table of Contents

Ford E-Series 6.0L DieselBeginning Model Year: 2006

Special instructions for these modelsPart locations may differ slightly dependent onthe vehicle model.

Be sure to check WWW.techwebasto.com forthe latest addition of this manual.

DOC. P/N 5001112B KIT P/N 5001182B Printed in USA Webasto Product N.A., Inc.

Torque Wrench

ForewordParts List 3Vehicle Information 3Scope and Purpose 3Symbol Identification 4General References 5Preparation 5Heater Installation Site 5InstallationComponent Break-down - (Typical) 6Universal Mounting Plate 7Mounting the Air Top 2000 Heater 8Integration into Fuel System 10

Exhaust Routing and Installation 13Combustion Air Intake 13Installing the Electrical Harness 14Rheostat Control Dial Installation (Standard) 14Optional Timer Installation 14Power and Ground Connections 15Optional Timer Wiring Diagram 16Wiring Schematic - Optional Timer 17Wiring Schematic - Rheostat Control Dial 18Concluding Work 19Heater Maintenance 20

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 special Webasto

training, technical information, special tools and special equipment. • 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 properly complete the necessary proce-dures.

• ALWAYS carefully follow Webasto installation and repair instructions and heed all WARN-INGS.

• Never install the heater in enclosed areas where combustible fumes may be present.• 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.

Parts List

Vehicle Information

ForewordThis installation requires special expertise from a Webasto training course to install a Webasto Air Top 2000, which means that it may only be installed by a specially trained workshop or dealership. Webasto cannot accept any liability for faults and damage caused by the system being installed by untrained personnel.

Scope and PurposeThese non-binding installation instructions are intended to support authorized Webasto trained distributors,dealers and personnel in the installation of the Air Top 2000 and BlueHeat Heaters.

These non-binding installation instructions apply to the vehicles listed on the front cover of this installationdocument 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” Air Top 2000 must be followed. Acknowledged engineering conventions must be observed for the installation work.

CAUTIONLocation of heater, 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.

ATTENTIONAll relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary heating devices must be observed!

Quantity Part Part Number

1 Air Heater 5001151B

1 Installation Kit 5001182B

Manufacturer Model Year Engine Type

Ford Econoline Beginning 2006 6.0 Liter - Diesel

4

BlueHeatTM Ford E-Series

Symbol Identification

Symbols that define sections in manual

Mechanical Preparation

Electrical

Fuel

General Symbol Descriptions

Warning

Caution

Flammable or Combustible

Exhaust

Combustion Air Intake

Refer to Webasto or Manufacturer Manual

Attention

Line of Sight/Item Location on Vehicle

Ford E-Series BlueHeatTM

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.

Heater Installation Site

ATTENTION For this application the Webasto Air Top 2000 was mounted to the floor of the vehicle, forward of the right-rear wheelhouse. Installation of the heater is not limited to this location. However, the heater must be securely mounted in a location which provides a good seal from the exterior of the vehicle.

– (1) Webasto Air Top 2000 Heater

Fig. 1

1

6

Ford E-Series

Component Break-down - (Typical)Some components may be different or not included in the vehicle specific kit purchased.

BlueHeatTM

7

Ford E-Series

Universal Mounting PlateA mounting template has been included with the heater kit for ease of installation.

The template details all required hole locations and clearances. Also, check for clearance around sub-floor cross-mem-bers, structures and heat sensitive components before proceeding with installation.

TEMPLATE NOT TO SCALE

100 mm (4 in.) Hole

8 mm (5/16 in.) Drill Bit

NOTE:ALLOW 155mm (6 in.) CLEARANCE FOR DUCTING

BlueHeatTM

8

Ford E-Series

Mounting the Air Top 2000 HeaterCAUTIONAlways check for obstructions under vehicle before drilling. Remove obstructions if necessary.

Using a hole saw or similar large hole cutter, cut a 100 mm (4 in.) hole in the center of the template outline.

Use a 8 mm (5/16 in.) drill bit to drill mounting holes.

– (1) Heater template

Temporarily place the heater mounting plate in position and insert 4 locator bolts through plate. Cut the flooring material using the heater mounting plate as a template. Remove the mounting plate and flooring material.

– (1) Flooring material

Install gasket on heater as shown in Figure 4.

– (1) Bottom of heater– (2) Gasket

Fig. 2

1

Fig. 3

1

Fig. 4

1

2

Ford E-Series

9

Install heater mounting plate on heater and apply foam seal.

– (1) Foam seal – (2) Heater mounting plate– (3) M6 nut / washer assembly

ATTENTIONThe exhaust tube can also be installed on the heater at this time. Refer to Exhaust Routing and Installation on page 13.

Install air intake tube and fuel line coupler on heater before mounting heater to floor.

– (1) #10 hose clamp– (2) Air intake tube– (3) 90° fuel coupler shown (use straight coupler

for E -Series)– (4) 10mm fuel line clamp

CAUTIONTorque all mounting bolts evenly. Do not over-tighten mounting fasteners! Mounting plate distortion may occur resulting in fan motor failure. Ensure the heater base and gasket covers the entire hole.

Mount Heater / Plate Assembly to vehicle using 6 mounting bolts and locknuts.

– (1) Heater– (2) M6 mounting bolt, M6 locknut - 6 ea.

Fig. 5

1

2

3

Fig. 6

1

2

3

4

Fig. 7Fig. 7

1

2

10

Ford E-Series

Integration into Fuel System

ATTENTIONEnsure the fuel lines are fully seated within the fuel line couplers and any 90 degree bends are not buckled. Refer to Figure 8.

Tighten all fuel line clamps to 1.0 - 1.4 Nm (8.8 - 12.4 lb.-in.)

Auxiliary Fuel Pickup ConnectionATTENTIONThe sending unit shown may look different than the one installed on the vehicle, but the procedure for installing the fuel pickup is the same.

Lower vehicle fuel tank in order to access fuel sending unit.

Remove cap from auxiliary fuel pickup tube and install 90 degree fuel coupler provided.

Connect heater fuel line to fuel line coupler and tighten hose clamps.

ATTENTIONSecure heater fuel line to vehicle fuel line with cable ties.

– (1) 90° fuel line coupler– (2) Axially fuel pickup tube– (3) Fuel sender– (4) Vehicle fuel line– (5) Heater fuel line– (6) 10mm fuel line clamp (2-ea.)

Fuel Pump Installation

Mount the fuel pump using an existing hole in the left framerail. See Figure 10 for location.

– (1) P-clamp, M6x20 bolt, and M6 nut– (2) Fuel pump– (3) Left framerail

Fig. 8

Fig. 9

1 2

6

5

43

Fig. 10

2

3

1

Ford E-Series

11

ATTENTIONAlways 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.

Route the heater fuel line from the auxiliary fuel pickup tube to the inlet side of the fuel pump (cut to length) and connect using fuel line coupler and clamps.

Connect the remaining section of fuel line to the outlet end of the fuel pump using the fuel line coupler and clamps.

– (1) Outlet fuel line coupler– (2) Fuel pump– (3) Inlet fuel line coupler– (4) 10mm clamp - (4 ea.) – (5) Fuel line from auxiliary fuel pickup

Route fuel line from fuel pump outlet to the passenger side of the vehicle under vehicle crossmember.

Secure fuel line with cable ties.

– (1) Vehicle crossmember– (2) Fuel line with plastic loom– (3) Cable tie

Route fuel line from the crossmember to the heater mounting location and connect to heater with fuel line coupler installed previously.

– (1) Fuel line coupler– (2) Fuel line– (3) 10mm clamp

Fig. 114 35 2

1

Fig. 12

2

3

1

Fig. 13

1

2

3

12

Ford E-Series

Connect fuel pump harness to fuel pump extension harness.

– (1) Fuel pump harness– (2) Fuel pump extension harness

Route the fuel pump extension harness to the fuel pump mounting location following the fuel line.

Secure the wiring harness to the vehicle with cable ties.

– (1) Vehicle crossmember– (2) Fuel pump electrical harness– (3) Heater fuel line

Connect fuel pump harness electrical harness to fuel pump.

– (1) Fuel pump harness– (2) Fuel pump

Fig. 14

1 2

Fig. 15

1

2

3

Fig. 16

1 2

Ford E-Series

13

Exhaust Routing and InstallationInstall exhaust tube (pre-cut to 508 mm or 20 in.) on heater and route as shown in Figure 17.

Secure exhaust tube to heater mounting bolt with P-clamp, washer and nut provided.

Position exhaust insulator on exhaust tube to prevent exhaust tube from contacting vehicle underbody.

– (1) Exhaust insulator– (2) P-clamp, washer, and M6 nut– (3) Exhaust tube– (4) Exhaust clamp

ATTENTIONEnsure end of exhaust tube is pointing downwards and towards the rear of the vehicle.

Secure exhaust tube with p-clamp as shown in Figure 18.

– (1) Exhaust tube– (2) P-clamp, M6x20 bolt and M6 nut

Combustion Air IntakeRoute combustion air Intake tube over framerail.

– (1) Combustion air intake tube

ATTENTIONEnsure end of air intake tube is pointing downwards and towards the rear of the vehicle.

Bend end of air intake tube down and secure with cable tie as shown in Figure 20.

– (1) Air intake tube– (2) Right framerail– (3) Cable tie

Fig. 17

1 32

4

Fig. 18

2

1

Fig. 19

1

Fig. 20

1 2

3

14

Ford E-Series

Installing the Electrical Harness

Remove top access cover from heater and plug the harness into the control unit receptacle socket as shown.

ATTENTIONCheck your wiring! Ensure that all connections have been done in accordance with the wiring diagrams located in the back of this book. Sensitive electronic controls can be damaged if wired incorrectly!

– (1) Air Heater– (2) Heater wiring harness

Rheostat Control Dial Installation (Standard)

CAUTIONCheck behind panels for obstructions before drilling holes.

ATTENTIONBefore installing the heater control, please confirm the installation location with the customer.

Install rheostat control, refer to Figures 22 and 23 for correct installation, and connect wiring harness.

Secure wiring harness with cable ties.

ATTENTIONThe optical fiber must be in contact with the rotary knob.

Optional Timer InstallationATTENTIONThe optional 7 day timer can be installed in place of the rheostat switch (heater control) that comes standard with the air heater.

CAUTIONCheck behind panels for obstructions before drilling holes.

ATTENTIONBefore installing the timer, please confirm the installation location with the customer.

Secure wiring harness with cable ties.

Wire timer harness connector in accordance with the wiring diagram located on page 16.

Route timer harness between inner and outer body panels to timer location. See Figure 24.

Using timer mounting bracket as a template, drill two holes in inner body panel and install timer.

– (1) Cable tie– (2) Timer mounting bracket – (3) Timer control– (4) Inner body panel

Fig. 21

2

1

Fig. 22

Fig. 23

Correct

Incorrect

Fig. 24

1

3

2

4

Ford E-Series

15

Power and Ground ConnectionsATTENTIONApply silicone sealant to grommet after routing power and ground wires.

Route heater and timer power and ground wires through body grommet shown in Figure 25.

Secure power and ground wires to heater mounting bolt with p-clamp.

– (1) P-clamp– (2) Heater mounting bolt– (3) Power and ground wires– (4) Body grommet

Secure the power circuit fuse holder and excess fuel pump harness between the vehicle batteries using cable ties.

– (1) Right framerail (between batteries)– (2) Power circuit fuse holder– (3) Fuel pump harness

Lower battery tray to gain access to vehicle batteries.

Secure heater and timer power wires to battery positive terminal.

Secure heater and timer grounds to negative battery terminal.

– (1) Heater and timer power wires– (2) Battery positive terminal– (3) Heater and timer ground wires– (4) Battery ground terminal

Raise and secure vehicle battery tray.

ATTENTIONEnsure the ground lead going to the framerail is tightened to 25 Nm (18 lb-ft).

Fig. 25

12

3

4

Fig. 26

321

Fig. 27

4

3

1 2

16

Ford E-Series

Optional Timer Wiring Diagram

BlueHeat with optional timer 88206A (7-Day Digital Timer Model 1531 with Temperature Rheostat)

Battery Negative (4 & 12)

Blue (6)

Red (8)

White (9)

Battery Negative (4)(ground)

Dash Lights (1) (optional)

Battery Positive (10)

Battery Negative (12)

(ground)

Battery Positive (11)

Black (2)

BlueHeatTM

17

BlueHeatTM Ford E-Series

Wiring Schematic - Optional Timer

18

Ford E-Series BlueHeatTM

Wiring Schematic - Rheostat Control Dial

Rheostat Control Dial

Fuel Pump

19

Ford E-Series

Concluding Work 1. Install all vehicle parts, panels and components removed during heater installation.2. Secure all loose lines and cables with nylon cable ties.3. Spray the heater components and electrical connections with an anti-corrosive wax coating.

Final InspectionInspect installation for:

– loose fasteners.– Exhaust system routing and clamp tightness.– Combustion air intake tube routing and clamp tightness.– Loose fuel line clamps.– Routing of fuel lines and fuel lines securely tied and protected against chafing and related damage.– Loose wiring connections and battery connections.– Routing of wiring harness and wiring harness securely tied and protected against chafing and related

damage.

Initial Start-up1. Set time and day of week on heater timer according to operating instructions found in the owners man-

ual.2. Switch on the Webasto heater by means of the instant heat button on timer and check:

– Timer panel and instant heat indicator illuminates.– Initiation of start-up sequence.– Successful start-up and operation (heat produced at heater outlet).

ATTENTIONMore 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 and runs successfully. Should the heater fail to start or operate correctly, call your Webasto technical representative at:

1-800-555-4518

Ford E-Series

20

Heater MaintenanceThe Webasto BlueHeat heater is designed for minimal maintenance. Under normal circumstances it should be inspected for proper function at least once annually, preferably, just prior to the heating season.

To ensure trouble-free operation, the following should be part of an annual and periodical inspection:

1. Operate the heater a minimum of 10 minutes every month to keep fresh fuel in the system and the fuel pump lubricated.

2. Keep the heating air outlet clear of obstructions.3. Keep the heater inlet grille clear of obstructions.4. Inspect the combustion air tube and exhaust tube for obstructions and damage. Check to ensure they are

securely attached to the heater and vehicle. Repair damaged items where necessary.5. Inspect the fuel system and all connections for leaks. Tighten clamps if loose. Ensure fuel line is well

secured to the vehicle. Replace fuel filter if equipped.

21

Ford E-Series BlueHeatTM

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Mail to:Webasto Product N. A., Inc.15083 North RoadFenton, MI 48430Attention: Documentation Group

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Webasto Product N.A., Inc.

Technical Assistance HotlineUSA: (800) 555-4518Canada: (800) 667-8900

www.webasto.uswww.techwebasto.comOrg.01/2006 Rev. 06/2006 P/N 5001112B