Autonomous heater Webasto do-it-yourself repair

The Webasto autonomous heater is a very reliable device, but a breakdown can still happen. In most cases, failure is due to improper installation, improper operation or lack of maintenance.

Most often, the Webasto autonomous heater simply does not turn on in the event of a malfunction, however, with some malfunctions, abnormal operation of the device is simply observed.

Webasto autonomy has the following typical malfunctions:

• flame breaks;
• overheat;
• unstable operation (for example, difficulty starting).

In the event of a breakdown, the heater will signal its malfunction by showing an error code (a table with codes is presented at the end of the article).

The timer display will show an inscription in the form of the letter F and two numbers (this is the error code).

If there is no timer and there is only a switch, then the switch lamp will give a certain signal (blink code). The light bulb will give 5 short beeps and a number of long beeps. The number of long beeps is the error code. If the error code is 0, then the bulb will simply give 5 short beeps.

Also, abnormal operation of the heater may be indicated by extraneous noise during operation of the device.

On his own, the car owner can only check the condition of the fuses, as well as visually assess the condition of the heater.

Therefore, if visually all the fuses are intact and all the plugs are in place, then it is necessary immediately contact a specialized service center. For complete diagnostics and reading errors, you must have special Webasto Thermo Test software, as well as a special programmer and a plug adapter. All this is available only in a specialized service center.

Do-it-yourself repairs can damage the heater or the vehicle.

Webasto autonomy may show the following error codes:

Many assure that do-it-yourself repair and diagnostics of Webasto is a simple thing and accessible to everyone. Don't be gullible: like any device, the heater is a rather intricate system. If you are not very friendly with electricians, it is better not to meddle with Webasto: saving $ 10 on the services of specialists (and spending several hours of precious time in combination with several kilometers of nerve cells), you can repair up to an amount of 40-50 US dollars .

Experts also assure that they receive 50% of their earnings from heaters due to the preliminary intervention of the owners in them. In addition, abnormal work (or a complete failure to function) "Webasto" may be due to the systems associated with it, and not at all to personal whims.

Do-it-yourself repair and diagnostics of Webasto should begin with familiarization with the scheme - it is attached to the device by the manufacturer. And if you are not a professional electrician / mechanic, it is better to limit yourself to checking the simplest - they are also the most likely - breakdowns, and with complex ones, go to a service center.

Problems with fuel supply to the heater most often occur in cold weather and indicate that you may have forgotten at the same time to change summer diesel fuel to winter when you changed your car. If, after the car has settled in a warm box, the heater starts to work, change the fuel. There is no heated garage - connect a canister with the correct, winter diesel fuel to the Webasto and see if it starts working.If you have found the cause, you will have to lower the solarium, blow out the system, clean it, change the cleaning filtration, fill in a new one.

There are also more complex reasons for the non-delivery of fuel to Webasto.

• Diesel fuel does not reach the pump itself. At the same time, the sounds are sonorous, distinct, loud. The most common cause is air leakage due to depressurization of the fuel supply. Therefore, it is necessary to check the tubes;
• A solenoid valve can also ensure the absence of diesel fuel in the heater - for example, a plug has formed at the inlet to it. To check, you need an ohmmeter: the resistance on the winding in the normal state should be in the range of 136-154 ohms. For additional verification, several short pulses can be given to the valve with a frequency of up to 1 hertz and an amplitude between 8 and 11 V. In parallel, flushing fluid (carburetor is suitable) must be given to the tube. In many cases, no further action is required.

Anyone who lives peacefully with electrical circuits can move on if the failure of the Webasto is not caused by fuel problems.

The fuses F1-F3 are checked first. The burnt ones are changed, the performance of the heater is tested. However, if it was installed at the factory and connected to CAN bus, you will have to ring every fuse to a single one. The operation of Webasto is also dependent on controllers that are not included in the design - fuel level sensors, external as well as air inside the cabin, collisions, etc.

The next control object is the timer. The current is measured in the connector. If it is present, but the device is inactive, the timer itself must be replaced.

The power supply is checked in the contacts of the heater stove. At the same time, the terminals are also inspected: primitive oxidation can interrupt the supply of current, as a result of which Webasto is capricious. At the same stage, all wires are examined for breaks and frays. A common case: almost on the plug itself, the wiring breaks off without external signs, the insulation remains intact. So be careful and sensitive fingers.

We advise you to go deeper into the circuit only to very brave or electricians. And average drivers can go to the last checkpoint.

Webasto Diagnostics (webasto) Thermo Top do it yourself.

What can be done and how on one's own when repairing a wet Webasto stove?

First of all, measure your capabilities and experience with the complexity of the task. Therefore - decide - whether the task is up to the task. More than 50% of all heaters that are being repaired have passed through the hands of the owners. Many of them were initially with trifling breakdowns, or simply blocked by software and did not require mechanical intervention. However, after the repair of the owners, we also had the opportunity to earn. Do not fall into the number of such "repairmen", if in doubt, just carry / take the heater to the service station. Moreover, the failure of the heater may be due not to the heater itself, but to the associated vehicle systems.

And, if you still decide on an independent repair - then go ahead.

Let's start with the simplest checks. If the heater stopped working in cold weather, then most likely the problem is in the fuel supply system, or rather in the fuel itself. (More information about fuel and its composition can be found in the article). In this case, the check should be carried out in a warm garage in order to exclude the influence of the "summer" solarium on the work of Webasto. It should be noted that such problems appear already at a temperature of minus 15-18 degrees. You can also connect power from a separate container at the time of the test with obviously clean and good, winter diesel fuel. In any case, the fuel supply system should be purged and cleaned, the fuel filter should be replaced, and if there is none, put it in.

An indirect sign of the lack of fuel in the power system is the sound of the metering pump. By the way, it must be properly installed,

If the sound is sonorous and loud, then it is possible that diesel fuel does not enter the fuel pump itself. With “good, correct” operation, the sound is muffled and not loud. The cause may be a leak in the fuel line, air leakage.

You can check the integrity of the winding itself with an ohmmeter. Winding resistance at 20 degrees should be about 136-154 ohms. The operation of the valve can be checked by applying short pulses to it with an amplitude of about 8-11 volts with a frequency of 0.5-1 hertz. At the same time, a flushing liquid, such as carburetor cleaner, is supplied to the tube. Sometimes such a check operation is enough to bring the heater itself to life, if the cause of the failure was a blockage in the fuel line at the installation site of the solenoid valve.

The next stage of verification is the electrical part. First of all, you should make sure that the F1-F3 fuses are working.

Check the presence of supply voltages on the timer (connector X8). If the power comes to the timer, and the latter “no mu-mu”, then it is the reason. How to run Webasto without it will be described below.

If the heater was installed at the factory with a connection to the CAN bus, then literally check ALL fuses. Firstly, it will take a little time, secondly, make sure once again that they are in order, thirdly, it is not possible to specify a specific fuse for all possible variants of car modifications even within the same model, and, fourthly - the operation of the heater also depends on the state of the sensors that are not part of it. For example, from a fuel level sensor, from an external and interior air sensor, from a collision sensor, from the voltage of the on-board network.

Separately, you should check the power supply at the connectors of the stove itself (X1-X2) - plus and minus and the quality of the contacts. Often, in the most inaccessible places, almost in the plug itself, the wire breaks off or rots, while the insulation is not externally damaged.

If both power supply circuits - fuel and electric are normal, then the heater can simply be blocked as a result of past errors that have already been eliminated, but are still recorded in the memory of the heater control unit.

You can unlock the heater in three now forgotten ways:

3. Unlock as recommended by the manufacturer Webasto. Unfortunately, it does not always work, but nevertheless, there is a chance.

step 1 remove power from the heater control unit for 3 seconds.

Step 2 Apply power and turn on the heater using timer 1533 or remote control.

step 3 after 3 seconds, turn off the power to the heater control unit again

Step 4 Apply power to the heater control unit after 3 seconds.

Judging by the Webasto manuals, everything should work, and, by the way, it often works.

It is checked with an ohmmeter at a temperature of 25 degrees. The resistance of a healthy element is 0.2-0.4 Ohm

It is checked by applying a pulsed voltage with an amplitude of 10-12 volts with a frequency of 1-10 Hertz. The resistance of a serviceable pump is 5.2 ohms at a temperature of 20 degrees. A serviceable pump should provide a volumetric fuel supply in the amount of 36-45 grams for 3 minutes at a pump switching frequency of 7 Hertz.

It is checked with an ohmmeter at a temperature of 24 degrees. The resistance of a serviceable element is 2-4 Ohm when equipped with No. 1. The resistance of a serviceable element is 0.8-1 Ohm when equipped with No. 2

It should work when 12 volts is applied to it. The resistance of a healthy element is about 10 kOhm. However, you should focus on connecting the power directly.

At 20 degrees, the resistance of the element is 2-4 ohms.

Overheating sensor

At 20 degrees, the resistance of the element is 240 ohms.

The resistance of a working element is 136-154 Ohm at 20 degrees

Autonomous heater Webasto. Features of air, liquid systems. Complete set and installation features

A necessary condition on a long journey in the cold season is to maintain a comfortable temperature in the car.And here one of the best solutions would be a Webasto heater - an autonomous device that heats the air in the car to the required temperature.

In the article we will talk about what this device is, why it is needed, and also describe the process of self-installing the heater.

Heating of the machine by an autonomous system

To ensure a comfortable microclimate in the car, car stoves are most often used. However, they have a significant drawback - they only function when the car's engine is in operating mode.

However, this is not always possible, and therefore in some situations the driver has to freeze, complaining about the wrong clothes or shoes.

An electric heater can become an alternative to the stove, however, in this case there are nuances. And the most important thing is that the supply of electricity in a car is not infinite, and therefore it is not always possible to spend battery power on heating.

A familiar situation, isn't it?

The way out of this situation are autonomous car heaters. Of course, the price of such a device is much higher than that of a standard stove, but there are plenty of benefits from its operation.

What are these benefits?

• Firstly, an autonomous heater creates a comfortable temperature in the car cabin immediately after switching on.
  If with a stove we would have heard from the driver the usual “Be patient, we’ll start up and heat up now”, then in the case of an autonomous heat generator, you won’t have to freeze.

Note!
Some Webasto autonomous heaters are equipped with a module that enables the system to be switched on from a mobile phone or a special remote control.
In this case, you can start heating the passenger compartment in advance, and the car will be warm enough when you arrive.

Installing the device in the bus

• Secondly, the use of this device provides engine preheating. Thanks to this, even in severe frost, the car starts up very quickly, and the engine life is significantly saved.
• It is also worth mentioning such advantages as maintaining the temperature in the car during long-term parking (truckers and those waiting in lines at customs will appreciate it), quick glass heating, protection from freezing and fogging, etc.

Based on these advantages, Webasto heating devices can be recommended:

• Those who do not like to freeze in the car, or families who often carry small children in the car.
• For those who stand in traffic jams, queues, etc. for a long time. First of all, these are taxi drivers, couriers, truckers, drivers of special equipment, etc.
• And also for those who are trying to reduce the wear of the engine of their car and maximize its efficiency.

By design, autonomous heating systems are divided into air and liquid. Air systems are the most common category of devices.

How does an air heater work?

Webasto air autonomous heating system has the following design:

• The main element is a hermetically sealed combustion chamber.
• Under the action of the fuel pump, fuel enters it through an automatically adjustable valve with a built-in filter.
• The glow plug is responsible for starting the ignition process.
• The fuel-air mixture ignites and burns in a special device - a burner with a nozzle of a special shape. Air enters the nozzle of the burner with the help of a special pumping device, after which it passes into the heat exchanger.
• In the heat exchanger, the air warms up to the required temperature, and then, under the influence of the same supercharger, enters the passenger compartment.

The cooled air from the passenger compartment through the intake holes again enters the heater, where it heats up again.

Air heaters can be installed on almost any car, the dimensions of which allow the body of the device to fit. The features of air models are relatively low weight (up to 7 kg), as well as low fuel consumption. For an hour of operation of the unit in continuous heating mode, from 0.1 to 0.25 liters of fuel is burned, depending on the modification.

Liquid models of autonomous heat-generating devices from Webasto differ in slightly higher fuel consumption. For an hour of operation, such an installation consumes up to a liter of fuel.

Appearance of the fluid model

The principle of operation of this unit is to use the resources of the engine cooling system:

• At the user's signal (pressing a button, triggering a timer, a signal from the remote control or telephone), the heater pump starts.
• Under the influence of the pump, the pumping of the coolant begins.
• Then fuel is supplied to the combustion chamber, which ignites from the glow plug and burns out, transferring thermal energy through the heat exchanger to the coolant circulating through the pipes.
• Thanks to this, even with a “silent” engine, the regular heating system of the car is turned on, since the heated coolant begins to transfer energy to the stove.

The process is controlled by an automatic control system. If necessary, it increases or decreases the fuel supply to the combustion chamber, and also regulates the process of air injection into the system.

Above, we have already mentioned several times the automation of the system. It's time to take a closer look at what elements can be used to regulate the amount of fuel consumed and plan to maintain the temperature.

You can control the operation of the installation using the following devices:

• Mini-timer - makes it possible to program the start of warm-up for 24 hours, i.e. for a day. The regular mini-timer from Webasto has the ability to set three switching points, and for each of them set the duration of work.

• Modular timers are an improved version of the previous device. Using the modular timer, you can plan the start of heating during the week (for example, on Sunday the car is not needed - therefore the heater does not turn on).
• The remote control key fob has a functionality similar to the mini-timer. The range of the key fob is about 1 km, therefore, even while in the office, you can warm up the car by the time of the intended trip.
• The GSM module allows you to control the operation of the heater using a mobile phone.

Full-size heaters designed for trucks, buses and special equipment, of course, should not be mounted independently. But almost anyone can install a pre-heater (such as Webasto Termo Top E) on their car with their own hands.

First you need to buy the device itself, as well as a special installation kit.

As a result, we should have:

• Autonomous heater Webasto.
• Gasoline pump.
• Metal and plastic clamps for installing elements of the heating system.
• The heater control panel with a set of wires for connecting it to the car's electrical network (see also Why does the owner need a GAZelle wiring diagram).
• Set of hoses and nozzles.

As a rule, no additional parts are required for installation. In some cases, you may need to purchase a bracket to place the device itself inside the car.

In most cases, video recommendations for installing Webasto heaters can be found on the manufacturer's website.

Here is an instruction describing the main sequence of operations:

• The first thing to do is to decide on the installation location of the device under the hood of the car. As a rule, there is not enough space between the radiator and the engine, because the pipes of the air conditioner and its compressor interfere.
• It is optimal to install the device so that you can use the shortest possible gas line, as well as not too long pipes.
• Then we install a stainless steel bracket in the chosen place. The bracket can be painted to reduce the intensity of corrosion.

Note!
When installing the heater, displacement of the fuel pipes is allowed. To do this, they must be bent to the side and fixed.

• We drill holes in the bracket, to which we attach the guides of the device itself.
• We mount the inlet, and then we install the air outlet.
• We bring the gas pipeline to the device, connect it to the gasoline pump. Separately, we stretch the wires that provide power to the fuel pump. We also connect the wiring to the heater itself.

Photo of connected device

• We connect the heater to the cooling system through the pipe.
• We bring the wires into the cabin, after which we install the control panel on the panel (see also the article ZIL 130 wiring diagram: both in snow and in heat).

After completing all operations, we connect the power wires to the battery and test the system. Depending on the design features, the heater can start either immediately or after a few minutes of engine operation - this is due to the presence of air in the system.

Control panel on the panel

Webasto pre-launch heaters and heaters are devices whose convenience is difficult to overestimate. So if it is possible to install such a unit, then you should not save on your own comfort and vehicle resource (see also the article Kamaz Wiring: Understanding Modifications).

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Most experts are sure that do-it-yourself diagnostics and repair of Webasto is not so difficult. In fact, not everything is so simple: the heater has a rather intricate device. If a person does not understand much about electrics, it is better not to try to do everything on your own.Initially, it seems that you can save about ten dollars on the services of professionals, but if something goes wrong, you can spend about fifty dollars, as well as several hours of precious time. As the experts themselves note, they receive about half of their income from heaters solely due to the fact that the owners of the iron horse interfered with the operation of the device earlier. By the way, Webasto can fail not of its own free will, but due to systems related to it.

Do-it-yourself diagnostics and repair of Webasto is still possible, but you have to work hard. You need to start by studying the circuit that the manufacturer applies to the unit. If the driver is not a professional mechanic, the device should be checked for simple breakdowns. As for complex ones, it is better to entrust it to specialists working in service centers.

Interruptions in the supply of fuel to the heater often occur at a time when it is cold outside. They indicate that the driver probably forgot to switch to winter fuel. If, after the car has stood in a warm room for some time, the device starts to function again, you need to urgently switch to another type of fuel. Can't keep your car warm? Then you should connect a canister with winter diesel fuel to Webasto and check whether it will function. If the reason is nevertheless found, the fuel system should be cleaned of the summer solarium, and instead of it, fill in the one that is needed.

The following reasons are also distinguished due to which fuel does not enter the heater:

• Diesel fuel does not enter the pump. In this case, the driver will hear characteristic sounds. The most common reason for this is air leakage due to the fact that the fuel line has ceased to be airtight. The tubes need to be diagnosed.
• There may be no diesel fuel in the heater due to problems with the solenoid valve - a plug has appeared at the inlet to it. In this case, you will have to use an ohmmeter. In working condition, the winding should have a resistance of about 140 ohms. For better diagnostics, it is worth applying a couple of discharges to the valve, the frequency of which is 1 hertz, and the amplitude is 9 volts. At the same time, flushing fluid must be applied to the tube. Usually, you don't have to do anything else.

Anyone who reads electrical diagrams well can continue to work. If Webasto stopped working not due to fuel problems, you should immediately check the fuses F1-F3. If they burn out, you must immediately replace, after which the heater is checked for operability. But only if Webasto is factory installed, and it was connected to the bus, you will have to ring each of the fuses. The functioning of Webasto is largely dependent on sensors that regulate the fuel level, as well as on the air sensor in the cabin and on several others.

Another element worth paying attention to is the timer. You need to check the current in the connector. If it is, but the device still does not work, the timer will have to be changed.

It is also worth checking the power supply at the heater contacts. You should immediately look at the terminals: they could corny oxidize, which is why Webasto cannot function fully. At this stage, all wires should be checked for breaks and other defects. It is necessary to act as carefully as possible, because a wire defect may be present in the most unexpected place.

It's not worth going deeper into the scheme. Only those who are truly considered professionals can afford it. An ordinary driver can move on.

Webasto may stop working due to the fact that it is blocked due to errors that have been eliminated, but still remaining in memory. You need to act like this:

• For a couple of seconds, turn off the power from the control unit by removing the fuse.
• When the unit starts working again, Webasto is turned on using a remote control or a timer.
• Wait a couple more seconds and repeat the previous steps again.

Initially, it may seem that all the manipulations performed do not make much sense, but as practice shows, they still help. Subsequent repair and diagnostic work should not be performed. If nothing written in the article allowed you to deal with the problems, then it is really better to leave it to the professionals. Do-it-yourself diagnostics and repair of Webasto are allowed only within the limits indicated above. Sometimes, relying only on your own strength, you can face even greater difficulties. Naturally, you will have to spend an impressive amount, which not everyone likes.

The problem of starting a cold engine start at low temperatures is well known to every car owner. The power unit is difficult to start in cold weather, the degree of wear of loaded engine parts increases during such starts. Also, in winter, the comfort of vehicle operation is significantly reduced, since the warm-up time of the internal combustion engine and the interior space to an acceptable level can be significantly increased.

To effectively solve these problems, the car can be equipped with a preheater. There are several types of such devices, while liquid engine heaters of the Webasto type have the best autonomy and performance.

In this article, we intend to talk about how much Webasto costs with installation, what features and nuances it involves installing Webasto on a gasoline engine or diesel unit, and also how to install Webasto on a car yourself.

So, if the car is operated in a region with frosty and long winters, is used in similar conditions as a commercial vehicle, the driver wants to increase the comfort of operation in winter, etc., then the issue of installing a preheater becomes especially relevant.

In the case of Webasto, the answer will be yes, even taking into account the rather high initial cost of such a heater and its installation. On average, to buy and install Webasto will cost from 40 to 100 thousand rubles. for the device itself (depending on the type of vehicle), as well as about 15 thousand rubles. for installation.

However, such a pre-heater will allow you to start the engine in any frost, the overall resource of the internal combustion engine increases. We also note that the warming up of the engine and interior with an autonomous heater before a trip is noticeably reduced, which allows us to talk about fuel economy (especially in relation to gasoline cars).

On diesel engines, the Webasto installation allows you to solve the well-known problem of diesel fuel, which thickens in cold weather. It turns out that the installation of preheating is more or less profitable from an economic point of view, since fuel consumption is reduced, the engine is subject to less wear, which reduces the cost of its repair.

For maximum savings, many drivers (especially owners of passenger cars and small commercial vehicles) also prefer to install this equipment themselves. In other words, you will need a Webasto kit, installation instructions, the necessary tools and a place to work (it is advisable to have a garage with a lift or a pit).

Let's start with the fact that installing Webasto with your own hands involves a whole range of operations. If you are not confident in your abilities, do not have sufficient experience and suitable tools, then it is better to refuse self-installation and seek help from a professional installation center.

It should be remembered that incorrect installation can lead to fire and various problems during the further operation of the vehicle and the autonomous heater itself,as well as to the failure of individual elements of the internal combustion engine and / or Webasto.

As a result of fuel combustion, heat is generated, which heats the coolant (antifreeze or antifreeze) of the engine cooling system. The specified coolant passes through the heater heat exchanger, which is connected to the standard engine cooling system.

Coolant circulation occurs due to a separate pump, which is built into the heater. The pump forces the coolant to circulate in a small circle, as a result of which the engine is heated, as well as the elements of the internal combustion engine power system installed on the motor. The Webasto autonomous heater is a ready-made set of all elements and parts that are needed for installation. This kit includes:

• heater;
• electronic controller (control unit);
• coolant circulation pump;
• fittings for connection to the fuel system;
• fittings for connection to the cooling system circuits;
• dosing pump for fuel supply;
• separate heater exhaust system;
• separate air intake;
• mounting brackets and fasteners;
• installation instructions and operation manual;

As mentioned above, Webasto kits may differ, as they are designed for mounting on different types of engines and vehicles (petrol and diesel cars, minibuses, trucks, special equipment, etc.). Taking into account such features, the kits have differences in performance, basic characteristics and configuration.

In the process of selecting a heater for a particular car, this must be taken into account separately. For example, installing Webasto for a diesel engine on a gasoline car may, in some cases, require additional fasteners and adapters, which ultimately makes installation very difficult.

To begin with, the installation of a Webasto heater on a gasoline and diesel unit will require free access to both the upper and lower parts of the engine compartment. In parallel, it is necessary to implement good lighting. The installation process itself involves the following steps:

• The final stage can be considered the installation and connection of the battery, after which the first test run of the engine is performed. After such a start, you need to let the motor run for XX 5-10 minutes.
• Then you should check the level of antifreeze and add coolant if necessary. Next, a trial inclusion of the heater is carried out and the entire functionality of the device is checked.

Finally, we add that in some cases, during the first start-up, the heater may not work, since there is not enough fuel in the fuel line. In order for the fuel to fill the line, it will take a little time. After switching on again, the autonomous starting preheater should start working in the normal mode.