BlueHeat

Coolant Heater

2003 Chrysler Pacifica

3.5 Liter SOHC V-6

Installation Instructions

– 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 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 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.

DOC P/N 5000653A

KIT P/N 5000629A

BlueHeat

TM

2003 Chrysler Pacifica 3.5 Liter V-6

Table of Contents

Foreword

Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . I

Tools Required. . . . . . . . . . . . . . . . . . . . . . . . . . . I

Heater Installation Site . . . . . . . . . . . . . . . . . . . . II

Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . II

Installation

Electrical Harness - Overview . . . . . . . . . . . . . . . . 1

Fuse Holder / Relays / Resistor . . . . . . . . . . . . . . . 2

Electrical Harness Routing . . . . . . . . . . . . . . . . . . 2

Integration with HVAC Blower Motor . . . . . . . . . 2

Ignition ‘On’ Fuse Tap Connection. . . . . . . . . . . . 3

Timer Installation - Model 1533 . . . . . . . . . . . . . 4

Integration into the Fuel System . . . . . . . . . . . . . 5

Fuel Standpipe Installation. . . . . . . . . . . . . . . . . . 5

Foreword

Fuel Metering Pump Installation . . . . . . . . . . . . . 7

Fuel Line and Cable Installation . . . . . . . . . . . . . 7

Heater Preparation and Mounting . . . . . . . . . . . 8

Combustion Air Intake Installation . . . . . . . . . . . 9

Integration into the Coolant System . . . . . . . . . 10

Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . 10

Concluding Work . . . . . . . . . . . . . . . . . . . . . . . 11

Power Connection . . . . . . . . . . . . . . . . . . . . . . 11

Final Inspection and Initial Start-up . . . . . . . . . . 11

Basic Troubleshooting. . . . . . . . . . . . . . . . . . . . 12

Wiring Schematic - Part 1. . . . . . . . . . . . . . . . . 14

Wiring Schematic - Part 2. . . . . . . . . . . . . . . . . 15

Plumbing Schematic . . . . . . . . . . . . . . . . . . . . . 16

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 C/Z and BlueHeat coolant heaters.

These non-binding installation instructions apply to the 2003 model year Chrysler Pacifica 3.5 liter gasoline version, 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 Z/C/E 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.

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

Combination side-cut/crimping pliers

Hose clamping pliers

Hose cutting pliers

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

Drill

2.5 mm (3/32 in.) drill bit

8.5 mm (21/64 in.) drill bit

9.5 mm (3/8 in.) drill bit

10 mm (25/64 in.) drill bit

Hacksaw

Utility Knife

Wire fish

Hoisting equipment and safety stands

Vehicle manufacturer’s service reference manual

I

2003 Chrysler Pacifica 3.5 Liter V-6 BlueHeat

TM

Heater Installation Site

The Webasto BlueHeat auxiliary coolant heater is to be installed at the right front corner, under the bumper as shown in the illustration below.

Mounting Location

Mounting Location

Heater Installed

Preparations

Heater Kit

1. Verify and identify all contents of kit.

Vehicle

1. Verify fuel content in tank.

CAUTION

For reasons of safety due to the possibility of fuel spillage during the installation of a fuel standpipe, it is recommended there be no more than 3/4 tank or less of fuel present.

If fuel quantity is greater than 3/4 of capacity, make provisions to reduce quantity of fuel.

2. Disconnect negative terminal of vehicle battery(s).

3. Remove headlamps and front facia.

4. Remove right front wheel and pull back splash shield.

5. Protect vehicle against soiling and damage with fender covers and seat covers.

II

2003 Chrysler Pacifica 3.5 Liter V-6

Electrical Harness - Overview

Universal Electrical Harness - Description

Legend for Figure 1

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 cir cuit, 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)

24

22

20

17

26

18

Fig. 1

25

19

23

1

16

21

2

12

15

3

4

8

5

6

7

9

10

11

13

14

1

2003 Chrysler Pacifica 3.5 Liter V-6

Fuse Holder

Relays and

Resistor

Assembly

Fuse Holder / Relays / Resistor

ATTENTION

The electrical harness is a two-part assembly. Before installing, cut wire tie holding the negative side HVAC blower harness (with relay K3) to the main harness and separate.

– Mount K1 and K2 relays (2/1) to bracket (2/3) using hardware provided in kit.

– Install resistor (2/2) on bracket (2/3) with hardware provided in kit.

7

1

1 2

– Secure bracket (3/3) and heater harness ground wire

(3/5) to strut tower (3/4) using existing vehicle hardware as shown in figure 3.

– Fasten fuse holder to bracket assembly or vehicle structure using nylon wire tie (Image not available).

7

6

4

3

2

1 2

5

6

Electrical

Harness

Routing

Electrical Harness Routing

– Route timer (4/7) and blower control harness (4/8) through gromet (4/6) in vehicle bulkhead.

Fig. 4

Integration with HVAC Blower Motor

ATTENTION

It is permissible to cut excess length from blower control wiring harnesses.

9

HVAC

Blower

Control

Harness

Integration

– Locate vehicle blower motor (5/10) under under passenger side of vehicle dash.

– Locate blower motor harness connector (5/9), cut blower motor positive and negative wires approximately 2 inches from connector (5/9).

– Mount K3 relay under dash (Image not available).

2

Fig. 5

10

3

4

5

3

4

5

7

8

2003 Chrysler Pacifica 3.5 Liter V-6

Make HVAC Blower wiring connections as follows:

Position 1

– Connect to chassis ground

Position 2

– Crimp green wire to green wire

Position 3

– Cut, strip and crimp

Position 4

– Cut, strip and crimp

Position 5

– Cut, strip and crimp

Position 6

– Cut, strip and crimp

3

4

5

ATTENTION

Check your wiring! Ensure that all connections have been done in accordance with the accompanying wiring diagram (Fig. 6). Sensitive electronic controls can be damaged if wired incorrectly!

Additional

– Secure HVAC blower control wiring to vehicle structures with nylon wire ties (Image not available)

2

1

6

Fig. 6

Legend for Figure 6

A From Webasto Heater X1

B 12 VDC ignition ‘On’ fuse tap

C HVAC control module

M HVAC blower motor

X Cut wire 50 mm (2 in.) from HVAC motor

F3 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)

1 2

Ignition ‘On’

Fuse Tap

Installation

Ignition ‘On’ Fuse Tap Connection

– Route the blue fuse tap wire (7/1) to fuse panel as shown in figure 7.

– 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 (7/2).

3

Fig. 7 - Example only

2003 Chrysler Pacifica 3.5 Liter V-6

Timer

Installation

Timer Installation - Model 1533

ATTENTION

Before installing the timer, please confirm the installation site with your customer.

CAUTION

Before drilling into any panels, ensure there are no hidden components behind the panel that may be damaged or interfere with the timer installation! If necessary, to avoid damaging components, remove the panel before drilling holes.

ATTENTION

DO NOT OVERTIGHTEN MOUNTING SCREW!

Overtightening mounting screw will cause stress on the timer resulting in irreparable damage to the LED display.

Fig. 8

Position 1: (Sample Location Only)

– Translated template with instructions (see Figure 8)

– Screw DIN7981 B3.5x19

– Timer harness connector (Click in)

– Tighten mounting screw - max. 0.8 Nm (7.0 lb-in.).

1

Fig. 9

4

Integration into the Fuel System

WARNING

Full to partially filled fuel tanks are heavy and awkward to handle. Before removing fuel tank to gain access to the sender unit, ensure tank is near empty. To avoid accidents and injury to personnel, make sure tank is well supported while removing mounting hardware.

Fuel

Standpipe

Installation

– Remove the fuel tank from the vehicle following the manufacturer’s recommended service procedures.

– Remove the drivers side fuel sender (10/1) from the fuel tank following the manufacturer’s recommended service procedures.

1

2003 Chrysler Pacifica 3.5 Liter V-6

Fig. 10

WARNING

Fire and explosion risk! Do not use an electric power drill to bore into the sender unit as vaporizing fuel can be ignited. Keep all sources of ignition away from the fuel tank and work area.

– Bore an 8 mm (5/16 in.) hole (11/2) through the fuel sender at the location shown in Figure 11.

1

– Cut fuel standpipe tube (12/3) to 165.1 mm (6.5 in.) in length as shown in figure 12.

– Bend tube (12/3) as necessary to clear moving parts.

Fig. 11

2

5

Fig. 12

3

2003 Chrysler Pacifica 3.5 Liter V-6

Legend for Figure 13

1 Banjo Bolt

2 Banjo Fitting

3 Standpipe

4 Upper Sealing Washer

5 Fuel Tank Sender Unit

6 Lower Sealing Washer

7 Lock Nut

Fig. 13

– Install fuel standpipe with banjo fitting (14/3) outlet aligned as shown.

– Refer to Figure 13 for component installation sequence

– Tighten lock-nut to 9.0 - 9.5 Nm (80 - 84 lb-in.)

5

– Return fuel sender (14/5) to fuel tank and install according to manufacturer’s recommended service procedure.

– Connect supplied section of fuel line to fuel standpipe outlet (14/3) using a fuel line coupler and 2 clamps.

– Tighten clamps fully and torque to 1.0-1.4 Nm (8.8-

12.4 lb-in.)

Fig. 14

ATTENTION

Observe Figure 15 for correct fuel line connecting.

– Protect heater fuel line with loom provided in kit.

– Use nylon wire ties to secure heater fuel line to existing vehicle fuel line before installing the fuel tank.

– Assemble and install the fuel tank according to manufacturer’s recommended service procedure.

Fig. 15

3

1

2

3

4

5

6

7

6

2003 Chrysler Pacifica 3.5 Liter V-6

Fuel Pump

Installation

Fuel Line and Cable

Installation

– Pre-assemble two 90 degree rubber fuel line adapters

(16/5) with two hose clamps (16/1) each.

– Push rubber fuel line adapters onto pump outlet (16/4) and inlet (16/2)

– Tighten inboard hose clamps (16/1) to 1.0-1.4 Nm

(8.8-12.4 lb-in.).

– Fit P-clamp (16/3) around fuel pump (16/8).

– Mount fuel pump (16/8) to exhaust hanger (16/6) using bracket (16/7) supplied in kit.

CAUTION

Ensure fuel line does not come into contact with hot exhaust components or other sources of extreme heat.

Ensure fuel line is kept away from moving parts.

– Route the fuel line (17/9) over to the fuel pump (17/8).

ATTENTION

Fuel line must be cut using a sharp razor knife or razor.

DO NOT cut with side cutters, scissors or similar tools as doing so will cause a restriction inside the fuel line.

– Trim fuel line (17/9) to length and connect to fuel pump inlet adapter (17/5).

– Tighten clamp (17/10) to 1.0-1.4 Nm (8.8-12.4 lb-in.)

5

10

Fig. 17

1

2

8

9

8

8

3 4 1 5

7

11

6

– Connect remaining section of fuel line to fuel pump outlet adapter (18/5).

– Tighten clamp (18/12) to 1.0-1.4 Nm (8.8-12.4 lb-in.)

– Route heater fuel pump electrical harness (18/11) to fuel pump location following vehicle fuel lines and cut to length.

– Install electrical connector on fuel pump wiring harness per instructions found with connector.

– Connect fuel pump harnesss (18/11) to fuel pump

(18/8).

Fig. 18

5

12

– Cover heater fuel line (19/13) with loom (19/15) before routing to heater mounting location.

13

15

– Route heater fuel line (19/13) along vehicle fuel lines

(19/14) up to heater mounting location.

– Secure heater fuel line (19/13) and heater fuel pump electrical harness to vehicle fuel lines (19/14) with nylon wire ties.

Fig. 19

7

14

FRONT

2003 Chrysler Pacifica 3.5 Liter V-6

Heater Preparation and Mounting

– Raise and support vehicle on safety stands.

– Remove front fascia (bumper) according to the manufacturer’s recommended service procedures.

– The Webasto auxiliary coolant heater is installed behind the bumper, on the passenger side of the vehicle, just below the air intake tube.

Fig. 20

– Install inboard heater mounting bracket (21/2) on heater with three EJOT screws (21/1) provided in kit.

– Torque tighten screws (21/1) to 10 Nm. (88.5 lb-in.)

2

1

Heater

Bracket

– Install outboard heater mounting bracket (22/3) on heater with three EJOT screws (22/1) provided in kit.

– Torque tighten screws (22/1) to 10 Nm. (88.5 lb-in.)

Fig. 21

3

– Position auxillary coolant heater (23/4) in mounting location.

– Secure outboard heater mounting bracket (23/6) to vehicle frame (23/5) using hardware provided.

Fig. 22

4

1

8

Fig. 23

6

5

– Secure inboard heater mounting bracket (24/2) to vehicle frame with hardware provided. Refer to positions 1 and 3 for hardware location.

2003 Chrysler Pacifica 3.5 Liter V-6

1 2

Fuel Line

Connection

– Preassemble fuel line adapter (25/5) with two clamps

(25/6). Do not tighten clamps.

– Install fuel line adapter (25/5) on heater fuel inlet nipple and tighten clamp (25/6).

– Insert fuel line (25/4) into fuel line adapter (25/5) until it reaches the inlet nipple and tighten clamp (25/7).

– Tighten clamps fully and torque to 1.0-1.4 Nm (8.8-

12.4 lb-in.)

Fig. 24

4

3

5

Combustion

Air Intake

Combustion Air Intake Installation

– Install split end of combustion air intake tube (26/8) on air intake port of heater and secure with narrow band hose clamp (26/9).

– Route combustion air intake tube (26/8) over top of heater towards the rear.

– Thread combustion air intake silencer into the end of the combustion air tube (Image not available).

– Clamp the silencer to the vehicle body with the silencer clamp provided.

– An available 6 mm (1/4 in.) hole on the body sheet metal can be used to anchor the silencer. If a hole is not available, bore a 6 mm (1/4 in.) hole for anchoring.

Fig. 25

Fig. 26

ATTENTION

The silencer must be pointed in a downward direction!

8

9

7

6

9

2003 Chrysler Pacifica 3.5 Liter V-6

Integration into the Coolant System

NOTE:

For an overview of the coolant circuit, turn to the back section of this manual for a plumbing schematic.

NOTE:

Torque all hose clamps to 1.5 - 2.0 Nm (13 - 18 lb-in.).

– Clamp coolant supply hose (27/2) with hose clamping pliers (27/1) as shown.

– Cut (27/2) coolant supply hose as shown.

Preparing

Heater

Hoses For

Connection

– Cut the formed hose supplied with kit in half and cover with protective sleeving provided.

– Remove 90 degree end from hose (28/3) and install on heater outlet with hose clamp (28/4).

– Remove 180 degree end from hose (28/5) and install on heater inlet with hose clamp (28/6).

– Route heater coolant hoses up to the engine compaartment and make the following connections:

1. Using adapter and two hose clamps, connect heater coolant inlet hose (28/5) to vehicle coolant hose going into the engine block.

2. Using adapter and two hose clamps, connect heater coolant outlet hose (28/3) to vehicle coolant hose going into the heat exchanger.

– Secure heater hoses with nylon ties where possible.

Fig. 27

6

Fig. 28

Exhaust

System

3

Exhaust System

– Place exhaust clamp over one end of exhaust tube

(29/8).

– Connect exhaust tube (29/8) to exhaust port of heater.

– Secure with exhaust clamp (Image not available).

– Place exhaust clamp over end of exhaust tube (29/8).

– Install exhaust tube insulators (29/9) on exhaust tube

(29/8) as shown.

– Connect exhaust tube (29/8) to exhaust muffler (29/7).

– Secure muffler to the vehicle body with an ‘L’ bracket provided.

– Bend exhaust tubing (29/8 & 29/10) to ensure there is no contact with heat sensitive vehicle components including the front fascia once it is reinstalled.

Fig. 29

ATTENTION

Keep exhaust muffler outlet (29/10) pointed downward as shown

10

5 4

7

9

8

1

2

10

2003 Chrysler Pacifica 3.5 Liter V-6

Concluding Work

Power Connection

– Connect heater power lead (30/2) to the positive terminal (30/1) of the battery.

– Connect battery ground cable(s).

FR

O

N

T

1

Fig. 30

2

Final Inspection and Initial Start-up

Final

Inspection

Final Inspection

1. Check all fasteners to ensure system is secure.

2. Check routing of coolant lines and ensure coolant lines are securely tied and protected against chaffing and related damage.

3. Check routing of air intake and exhaust lines and ensure lines are secure. Keep hot exhaust components away from heat sensitive vehicle components and fuel lines.

4. Check routing of fuel lines and ensure fuel lines are securely tied and protected against chaffing and related damage.

5. Check routing of wiring harnesses and ensure wiring harnesses are securely tied and protected against chaffing and related damage.

6. Check for loose wiring connections and battery connections.

7. Check operation of vehicle heater fan with Webasto heater OFF.

Initial Startup

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

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. If heater should fault to the lock-out mode, which is possible after three start attempts, refer to “Troubleshooting” and follow directions under “Heater Lockout Reset Procedure.” No further start attempts are possible until the lockout condition is cleared.

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.

7. Install all vehicle components removed during heater installation.

8. Place Owners Manual and related documentation in vehicle.

11

Basic Troubleshooting BlueHeat

TM

Coolant Heater

Basic Troubleshooting

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 (800) 555-4518

In Canada, call (800) 667-8900

CAUTION

Advanced troubleshooting requires comprehensive knowledge about structure and theory of operation.

Advanced troubleshooting of the heater and components 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 to ensure proper battery performance.

• 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.

Heater Lockout Reset Procedure

The BlueHeat is designed with a lockout safety feature built into 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 F1

(15 Amp), reinsert after 5 seconds.

2. Cycle timer or switch off and then back on once more. Remove fuse F1 once again and reinsert after 5 seconds. Heater should attempt to start in 10 seconds after inserting fuse. Coolant temperature must be below the lower threshold before heater will attempt to start.

12

BlueHeat

TM

Coolant Heater

General Malfunction Symptoms

The following table lists possible malfunction symptoms and remedies.

Basic Troubleshooting

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 tubing 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 tubing for obstructions

PC Diagnostics Interface Kit

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.

13

Schematics

Wiring Schematic - Part 1

2003 Chrysler Pacifica 3.5 Liter V6

14

2003 Chrysler Pacifica 3.5 Liter V6

Wiring Schematic - Part 2

Schematics

15

Schematics

Plumbing Schematic

2003 Chrysler Pacifica 3.5 Liter V6

16

Org. 06/2003 Rev. N/A P/N 5000653A

Webasto Product N.A., Inc.

Technical Assistance Hotline

USA: (800) 555-4518

Canada: (800) 667-8900 www.webasto.us

www.techwebasto.com