Autonomous heater webasto DIY 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, an abnormal operation of the device is simply observed.

Autonomy Webasto has the following typical faults:

• flame breaks;
• overheat;
• unstable work (for example, startup difficulties).

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 will give 5 short signals and a number of long ones. The number of long beeps is an error code. If the error code is 0, then the light will simply give 5 short beeps.

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

The car owner himself 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... To fully diagnose and read errors, you need a special Webasto Thermo Test software, as well as a special programmer and an adapter plug. All this is available only in a specialized service center.

Self-repair can damage the heater or the vehicle.

Autonomy Webasto can show the following error codes:

Many people claim that do-it-yourself Webasto repair and diagnostics is a simple thing and accessible to everyone. Don't be gullible: like any device, the heater is a rather sophisticated system. If you are not very friendly with an electrician, it is better not to meddle in a showdown 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 refurbish to an amount of 40-50 US dollars ...

Experts, however, assure that they receive 50% of their earnings on heaters due to the preliminary intervention of the owners in them. In addition, non-routine work (or complete refusal 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 diagram - 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 the most likely - of breakdowns, and with the complex ones, go to the service center.

Problems with the supply of fuel to the heater most often occur in cold weather and indicate that you may have forgotten at the same time to change the summer diesel fuel for the winter one when you changed your car's shoes. If the heater starts working after settling the car in a warm box, change the fuel. No heated garage - connect a canister with the correct winter diesel fuel to Webasto and check if it starts working.If you find the reason, you will have to drain the solarium, blow through the system, clean it, change the cleaning filtration, fill in a new one.

There are also more complex reasons for not receiving fuel at Webasto.

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

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

Fuses F1-F3 are checked first. The burned-out ones change, the heater's performance is tested. However, if it was installed at the factory and connected to CAN bus, you will have to ring each fuse to the last one. The operation of Webasto is also dependent on controllers that are not included in the design - fuel level sensors, external and also air inside the cabin, collisions, etc.

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

We advise only very brave or electricians to delve deeper into the circuit. And the average driver can skip to the last checkpoint.

Diagnostics Webasto (webasto) Thermo Top do it yourself.

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

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

And, if all the same decided on an independent repair - then go ahead.

Let's start with the simplest checks. If the heater stops working in cold weather, then most likely the matter 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 must 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 similar problems appear even at temperatures of minus 15-18 degrees. You can also connect power from a separate container at the time of the test with a known 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 on.

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 installed correctly,

If the sound is loud and loud, then perhaps diesel fuel does not enter the fuel pump itself. With "good, correct" operation, the sound is muffled and low. The reason may be a leak in the fuel line, air leaks.

You can check the integrity of the winding itself with an ohmmeter. The winding resistance at 20 degrees should be about 136-154 ohms. The operation of the valve can be checked by applying to it short pulses with an amplitude of about 8-11 volts with a frequency of 0.5-1 hertz. At the same time, flushing fluid, 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 reason for the refusal 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 properly.

Check the presence of supply voltages on the timer (connector X8). If the power comes to the timer, and the last one is "no mu-mu", then there is a reason in it. How to start Webasto without it is described below.

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

If both power circuits - fuel and electrical - 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.

The heater can be unlocked in three, now forgotten ways:

3. Unlocking on the recommendation of 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 supply power and turn on the heater using timer 1533 or remote control.

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

Step 4 After 3 seconds, apply power to the heater control unit.

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. Resistance of a serviceable element 0.2-0.4 Ohm

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

It is checked with an ohmmeter at a temperature of 24 degrees. Resistance of a serviceable element is 2-4 Ohm with a complete set No. 1. Resistance of a serviceable element 0.8-1 Ohm with a complete set No. 2

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

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

Overheating sensor

At 20 degrees, the element resistance is 240 ohms.

Resistance of a serviceable element 136-154 Ohm at 20 degrees

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

A prerequisite for a long journey in the cold season is to maintain a comfortable temperature in the car.And here one of the optimal solutions will be the Webasto heater - an autonomous device that warms up 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-installation of the heater.

Heating the machine with an autonomous system

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

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 use up the battery charge for heating.

A familiar situation, isn't it?

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

What are these benefits?

• Firstly, the autonomous heater creates a comfortable temperature in the car cab immediately after switching on.
  If with the stove we would have heard from the driver the usual "Be patient, now we will start and heat up", then in the case of an autonomous heat generator, we will not 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 by your arrival the car will be warm enough.

Installing the device on the bus

• Secondly, the use of this device provides prestarting warm-up of the engine. Thanks to this, even in severe frost, the car starts up very quickly, and the engine resource 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 queues at customs will appreciate it), quick glass heating, protection from frosting 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.
• Those who spend a long time in traffic jams, queues, etc. First of all, these are taxi drivers, couriers, truckers, drivers of special equipment, etc.
• And also for those who are trying to reduce wear on 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.

This is how an air heater works

Air autonomous heating system Webasto has the following design:

• The main element is a hermetically sealed combustion chamber.
• Under the action of a fuel pump, fuel is supplied to it through an automatically controlled 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 specially shaped nozzle. Air enters the burner nozzle using a special injection device, after which it passes into the heat exchanger.
• In the heat exchanger, the air is heated to the required temperature, and then, under the influence of the same supercharger, it 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 to fit the device body.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 the 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.

Liquid model appearance

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

• Upon a signal from the user (pressing a button, triggering a timer, a signal from the remote control or telephone), the heater pump is started.
• 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, transferring thermal energy through the heat exchanger to the coolant circulating through the pipes.
• Due to this, even with a "silent" engine, the standard 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 about automating the work 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.

The installation can be controlled using the following devices:

• Minitimer - makes it possible to program the start of warm-up for 24 hours, i.e. for a day. A regular mini-timer from Webasto has the ability to set three switch points, and for each of them set the operating time.

• Modular timers are an improved version of the previous device. Using the modular timer, you can schedule the start of heating during the week (for example, you don't need a car on Sunday - that's why the heater does not turn on).
• The remote control has the same functionality as the mini-timer. The range of the key fob is about 1 km, therefore, even being in the office, you can warm up the car at 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 are certainly not worth installing on your own. But almost anyone can install a pre-heater (such as Webasto Termo Top E) on their own car.

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

As a result, we should have in our hands:

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

Typically, no additional installation parts are required. 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.

There is also an instruction describing the basic sequence of operations:

• The first thing that needs to be done is to decide on the place of installation of the device under the hood of the car. As a rule, there is not enough space between the radiator and the engine, since the pipes of the air conditioner and its compressor are in the way.
• 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 selected place. The bracket can be painted to reduce 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 rails of the device itself.
• We mount the inlet and then install the air outlet.
• We bring the gas line to the device, connect it to the gas pump. Separately, we extend the wires that provide power to the fuel pump. We also connect the wiring to the heater itself.

Photo of the connected device

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

After completing all operations, we connect the supply 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

Prelaunch heaters and Webasto heaters are devices, the convenience of which 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 Wiring Kamaz: we understand the modifications).

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Most experts are sure that diagnosing and repairing Webasto with their own hands is not so difficult. In fact, not everything is so simple: the heater has a rather intricate device. If a person does not know much about electrics, it is better not to try to do everything on your own.Initially, it seems that on the services of professionals you can save about ten dollars, 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 earnings on heaters solely due to the fact that earlier the owners of the iron horse interfered with the operation of the device. By the way, Webasto may fail not of his own free will, but in connection with the systems related to him.

Do-it-yourself diagnostics and repair of Webasto is still possible, but you have to work hard. It is necessary to start by studying the diagram 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 machine 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 can of winter diesel fuel to Webasto and check whether it will function. If the cause is nevertheless found, the fuel system should be cleaned of summer solarium, and instead fill the one that is necessary.

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 that air is leaking due to the fact that the fuel line is no longer sealed. You need to perform tube diagnostics.
• There may be no diesel fuel in the heater due to problems with the solenoid valve - a plug has appeared at the entrance 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, flush fluid must be supplied to the tube. Usually, you don't have to do anything else.

Anyone who is good at reading electrical diagrams can continue to work. If Webasto stopped working not because of fuel problems, you need to check fuses F1-F3 right away. If they are burnt out, they must be replaced immediately, 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 depends a lot on the sensors that regulate the fuel level, as well as on the cabin air sensor and several others.

Another element to look out for is the timer. It is necessary to check the current in the connector. If there is one, but the device still does not work, the timer will have to be changed.

It is worth checking the power supply at the heater contacts. You should immediately look at the terminals: they could corny oxidized, 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.

You shouldn't go deeper into the scheme. This can only be afforded by someone who is truly considered a professional. The regular driver can move on.

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

• Disconnect the power supply from the control unit for a couple of seconds by removing the fuse.
• When the unit starts working again, Webasto turns 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 made it possible 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 is not to everyone's liking.

The problem of starting a cold engine start at low temperatures is well known to every car owner. The power unit hardly starts up 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 pre-heater. There are several types of such devices, while the best autonomy and performance are possessed by liquid engine heaters of the Webasto type.

In this article, we intend to talk about how much Webasto costs with the installation, what features and nuances the installation of Webasto on a gasoline engine or diesel unit involves, 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 such conditions as a commercial vehicle, the driver wants to increase the comfort of use in winter, etc., then the question of installing a pre-heater becomes especially relevant.

In the case of Webasto, the answer will be in the affirmative, even taking into account the rather high initial cost of such a heater and its installation. On average, buying and delivering 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 the engine to start in any frost, and the total resource of the internal combustion engine increases. We also note that the warming up of the engine and the passenger compartment with an autonomous heater before the 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 repairing it.

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

To begin with, 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 from self-installation and turn to a professional installation center for help.

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 up 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.

The coolant is circulated thanks to a separate pump that is integrated into the heater. The pump forces the coolant to circulate in a small circle, as a result of which the engine heats up, as well as the elements of the internal combustion engine power system installed on the motor. The standalone Webasto heater is a ready-made set of all elements and parts that are required for installation. This kit includes:

• heater;
• electronic controller (control unit);
• coolant circulation pump;
• fittings for connecting 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 operating instructions;

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

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

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. At the same time, it is necessary to realize 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 start of the engine is carried out. After such a start, you need to let the motor run for XX for 5-10 minutes.
• Then you should check the level of antifreeze and add coolant if necessary. Next, a trial activation 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, the heater may not work, since there is not enough fuel in the fuel line. It will take a little time for the fuel to fill the line. After restarting, the autonomous pre-heater should start to work normally.