Webasto 2000 DIY repair

In detail: do-it-yourself webasto 2000 repair from a real master for the site my.housecope.com.

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.

Video (click to play).

Self-repair can damage the heater or the vehicle.

Autonomy Webasto can show the following error codes:

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Autonomous heater WEBASTO AT2000 ST tends to be blocked after several unsuccessful start attempts. If the heater is equipped with a conventional regulator, the blocking code is displayed by flashes of the green light - 12 long - 5 short flashes.

To unlock, with the heater turned on (the light is blinking), pull it out for 15 seconds. heater fuse, then turn the regulator knob to the off position. and insert the fuse back. After these manipulations, the heater should start working, and you just have to find out and eliminate the cause of the blockage.

Installation of the heater Webasto Air Top 2000ST (diesel) is carried out in accordance with the installation instructions and is registered in the technical passport of the car. When performing certified services at the Webasto technical station, the acceptance information must always be in the car.
Service without taking into account the requirements of the installation instructions means termination of the Webasto warranty period. The same condition applies when repairs are carried out by unqualified specialists or using non-original parts. In addition, claims regarding warranty obligations are accepted in the absence of evidence of violation of this Manual.
The first year of operation of the heater must be marked on the nameplate by erasing the rest of the year designations from it.
Installation of heaters Webasto Air Top 2000ST (diesel) on vehicles carrying dangerous goods must comply with the requirements of ECE R122 and EG / 2001/56 (standards for the transport of dangerous goods). In particular, heating of containers containing dangerous goods is not allowed.
Turn off heaters at petrol stations and in the immediate vicinity of flammable vapors and dust (near coal, fuel or grain storage facilities). Locking is carried out by means of the main switch or the car battery. If these conditions are violated, there is a possibility of failure of the heater and malfunctions in its operation. The heaters must not be turned on to heat places or containers with the presence of flammable substances, explosive gases and similar substances. Cannot be used wherever there is an explosion or fire hazard.
The heated air flow from the heater must not be directed towards explosive, flammable materials. It is inadmissible to use a heater that is not equipped with an outlet grille. If the heater is equipped with deflectors, in any position the outlet of the system must be open and free for air flow.
Switching on and using the heater is prohibited (including from a programmable timer or the Telestart remote control) in closed rooms (such as garages).
Flushing of the heater with water and other liquids is inadmissible; blowing with compressed air is also excluded.
The Webasto Air Top 2000ST heater (diesel) must be turned on for at least ten minutes every month.
In case of an atypical sound during the operation of the heater, smell of fuel, an uncharacteristic smell or strong smoke formation, the heater must be switched off, remove the fuse and consult an authorized Webasto service station.
When installing the heater, an insulating gasket must be installed between the mounting plane and the heater itself. In its absence, harmful exhaust gases will enter the vehicle interior. The gasket must be changed every time the heater is changed.
The service life of the heat exchanger of the air heater is 10 years, after which the element must be replaced with a new branded heat exchanger at the Webasto service station. When replacing, it is also necessary to install a new temperature limiter. The option when the air pipe and exhaust pipes pass through the passenger compartment also requires replacement every 10 years.
Heater Webasto Air Top 2000ST (diesel) runs on diesel fuel used in the car. The fuel used must correspond to the type of air heater indicated on the type plate - diesel - type D.
Fuel lines must be free from defects and must be sealed. A leak or the appearance of defects in the fuel lines of the heater indicates the need to block the heater and remove the fuse. It is necessary to eliminate the problems at the Webasto service station. Make sure that the fuel lines (mecanil hoses) do not touch the exhaust pipes. Such contact is a fire hazard. Thermal insulation must be used.
In the working area, the heater temperature should not be higher than 85 ° C.
The heater does not allow for loads and pressure, therefore, it must not be stepped on or put objects on it. The system should not be covered with clothes, rags, etc., however, such things should not be stacked near the air intake or heated air outlet. It is necessary to monitor the cleanliness of the air intake and heated air, the system must be free of debris and foreign objects. If dirt appears, it is necessary to remove all excess and ensure a free passage of air. After cleaning is allowed, the heater can be unlocked. If the overheating does not pass or recurs, then you need to contact the specialized Webasto service to eliminate the causes of the breakdown.

The complete set of the heater determines how the device is controlled - from a switch or from a timer (see below).In vehicles for the transport of dangerous goods - the method of activation only with the switch. The timer is started “manually”. When stopping the engine and when starting the loading and unloading device in such vehicles, the heater should be automatically turned off. After shutdown, for subsequent start-up, you must first turn off the heater using a switch or timer.

The heater Webasto Air Top 2000ST (diesel) is switched on by turning the switch knob in the extreme left position. Turning the knob to the right increases the temperature. Attention! The volume of the room affects the delay in heating it. The heater operation changes automatically in accordance with the difference between the reading measured by the heater sensor and the temperature on the switch.

General instructions

The heater can be precisely programmed to turn on at any hour - from 00.01 to 24.00 throughout the week. It is possible to configure up to three trigger points, but only one will be activated. By pressing the direct start button (), the heater starts to work continuously until the button is pressed again.

When the ignition is turned off in the continuous operation of the system, the heater is automatically turned off after 15 minutes (the display starts to show the indication of the remaining operating time).

The heater timer has an alarm clock and is used simultaneously with the switch. The combi-timer is equipped with the possibility of setting the temperature (as in the switch).

When the ignition is on, the timer displays the day of the week and the current time. The heater buttons and display are illuminated if it is on. When the power is connected to an unconfigured timer (hazardous goods transport vehicles - an exception), all buttons and images start flashing on the display (time and day of the week must be set).

The flashing characters are configured by pressing the "" buttons. If you do not press the button for about 5 seconds, the entered time is fixed. By pressing the "" button for more than 2 sec. the fast time counter starts.

Manual: Activates the () button.

Automatic: by means of a pre-set period of time.

Manually: by pressing the button ().

Automatic: end of programmed operation by timer or (during operation) by setting the remaining time.

Press the () button for at least 2 seconds, the symbol starts blinking, the "" buttons set the required value. Then the day of the week setting starts flashing - you need to set the necessary data.

Ignition on: displayed on screen

With the ignition off: press the button ().

Pressing the button “R”Makes the program number flash, using the” ”buttons set the heating start time. Then the day of the week starts flashing: set the desired day. Then again click on the button “R"(You enter the program 2, by pressing again"R”- to program 3, at the third - we return to the set time mode).

Click on “R”Until the screen shows the required program number. Repeated pressing of the button “R”Allows you to erase this program. As a result, the current time mode will appear without the number of this program.

Press the "" button for 3 seconds.

Installation is carried out only with the ignition off and the system running in the interval from 1 to 120 minutes. using the buttons "".

Only the required response time is programmed, not the day of the week. Press the button “R”Until the bell symbol appears

... Use buttons ”” to program the required time. The alarm signal is turned off after 5 minutes or by pressing any key.

Press the button “R”Until the bell symbol appears on the screen

- the alarm period appears on the screen. To erase it, you need to press the button “R"While the bell icon"S”Does not disappear from the display.

Press the power button installed in any convenient place, for example, in the sleeping compartment (additional option).

The start time is not programmable (even with a timer); the heater is switched on directly with the power button. The display shows the end time. It is possible to set the current time and alarm.

Heaters Webasto Air Top 2000ST (diesel) also function in ventilation mode, driving air without heating. An additional dedicated switch (optional) is used for this mode. Without this option, the heaters work only for heating. The rotary knob adjusts the ventilation mode.

In the event of a malfunction, check the connectors and all fuses in the system and eliminate any defects found.

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To diagnose a malfunction of a Webasto heater, a multimeter (tester) is needed, all measurements with a multimeter are carried out without disassembling the heater itself. When the self-diagnosis of the heater control unit did not reveal error codes, proceed.

1.Air intake,
2.air blower,
3.Liquid liquid nozzle,
4.Glow plug (candle) / flame sensor,
5.vaporizer mesh,
6.Plug connections,
7.Control unit with built-in temperature sensor,
10.Heat exchanger,
11.Combustion chamber,
12.exhaust,
13. fuel supply,
14.water pump,
15.Liquid inlet pipe,
16. Fuel metering pump.

Let's start with some simple checks.
First of all, you should make sure that the F1-F3 fuses are working properly.
1 -Heater Webasto did not start in frost, most likely in the fuel line, or rather in the fuel itself. So we do the launch check in a warm garage in order to exclude the influence of “summer” diesel fuel on the Webasto Thermo Top operation. The problem of a frozen fuel line manifests itself already at minus 10-15 degrees, but it is advisable to connect a separate container with good winter diesel fuel, connect a short fuel pipe to the heater intake, then a warm garage will not be needed.

Indirectly, by the sound of the fuel pump, you can determine the lack of fuel in the system. The sound of a fuel pump with fuel is dull, and without fuel, the clicks sound loud and loud, if there is no fuel in the pump, then it can be both freezing and suction (leakage) of air due to a weakened clamp or a dry hose
If the fuel pump does not click at all, then it may have sour from the trapped moisture or paraffin deposits, sometimes blowing air with a simultaneous short-term supply of supply voltage helps, it is not recommended to use liquid for cleaning the carburetors - it can corrode the rubber cuff.

The next stage of verification is the electrical part.

Check for the presence of a supply voltage on the mini-timer (connector X8). If the power comes to the timer, but it does not work, then the reason is in it. If the heater is installed at the factory with a connection to the CAN bus, then check ALL literally fuses, since 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 states of sensors not included in it.
We check the power supply at the connectors of the Webasto itself (X1-X2) - plus and minus (mass) and the quality of the contacts. There is no power supply to the stove, we check the wires, even if the corrugation is intact, the wire could rot.
If both supply circuits - fuel and electrical are normal, then the heater is possibly blocked as a result of unsuccessful start attempts,

Unblock the heater can be independently.
3. Unlocking according to the manufacturer's recommendation Webasto-
step 1 remove power from the heater control unit (console) 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 (remote control) again
Step 4 After 3 seconds, apply power to the heater control unit (panel).
Judging by the Webasto manuals, everything should work, and, by the way, it often works

Taking out the connectors in turn from the sockets, we measure with the tester everything that is indicated below according to the diagram and drawing, which indicates which of which.

Glow plugs
It is checked with a multimeter in ohmmeter mode at a temperature of 25 degrees. Resistance of a serviceable element 0.2-0.4 Ohm

Dosing pump
It is checked by applying a pulse voltage of 10-12 volts with 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.

glow plug
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

Antifreeze pump
Should work when 12 volts are applied to it. Working resistance 10 kOhm. However, you should focus precisely on connecting the power directly.

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

Overheating sensor
At 20 degrees, the element resistance is 240 ohms.

thermostat 0 ohm.

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

If the heater starts up, it doesn't work like that. then check with a stopwatch at what stage the heater fails.

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.

Anyone who peacefully gets 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 out every 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 courageous or electricians to delve deeper into the circuit. And the average driver can skip to the last checkpoint.

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Air Top 2000 is designed for heating with regulation of the desired temperature of the car cabin. All operations to control and regulate the temperature takes place directly through the control unit of the auxiliary heater. Also, through the control unit, you can set the desired time and temperature, "autonomous" will automatically regulate the temperature in the driver's cab.

The next stage of verification is the electrical part.

Taking out the connectors in turn from the sockets, we measure with the tester everything that is indicated below according to the diagram and drawing, which indicates which of which.

Glow plugs
It is checked with a multimeter in ohmmeter mode at a temperature of 25 degrees.Resistance of a serviceable element 0.2-0.4 Ohm

Antifreeze pump
Should work when 12 volts are applied to it. Working resistance 10 kOhm. However, you should focus precisely on connecting the power directly.

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

Overheating sensor
At 20 degrees, the element resistance is 240 ohms.

thermostat 0 ohm.

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

If the heater starts up, it doesn't work like that. then check with a stopwatch at what stage the heater fails.

Those who put dislikes, you probably know everything better than anyone else? ;)))
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Webasto brains don't work. Blower motor does not work. Cold soldering was the reason. Power resistors.

Disassembly of Webasta Thermo Top Z / C-D (Diesel) Music track1.Gunnar Olsen-Peridot Music track2.Gunnar Olsen-Late Night Snack Music track3.Gunnar.

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In winter, the Webasto autonomous pre-heater is a desirable mechanism for any motorist. The main purpose of Webasto is to warm up the engine before its operational start, so that the driver does not need to wait for warm-up. In addition, the device is connected to the passenger compartment heater, and in cold weather you do not have to get into a cold car. Therefore, if such a useful and, moreover, not cheap, device fails, the car owner is looking for opportunities to repair it as soon as possible. To find out the cause of the malfunction, Webasta diagnostics will be required.

It should be noted that the Webasto autonomous heater is a rather complex device. Handling it requires certain knowledge and skills. In addition, a heater malfunction may not be associated with the device itself, but with other vehicle systems.
Some, not very well versed in electrical devices, try to conduct diagnostics and repair of Webasto do it yourself. Such an attempt can lead to complete damage to the device. And then, instead of the expected savings on repairs in a car service, the car enthusiast will face significant additional costs. If you are confident in your abilities and are ready to take on troubleshooting on your own, you need to start by studying the device diagram that comes with the manufacturer.

For those who are not a professional mechanic, it would be most reasonable to limit themselves to diagnosing Webasto and eliminating the most simple and typical breakdowns.

If the diagnostics reveal serious problems, then it is better to contact the service center to fix them.

The following are the causes of common device failures:

Internal memory errors not saved. In this case, first of all, the fuel supply is checked.
Spontaneous crashes. If the device performs autostart or reclosing, the reason for this may be a malfunction in the circuit.
Error shutdown can occur due to malfunctioning of the control panel or electrical circuit. The heating switches off without saving the error. Otherwise, the error may persist, but upon restarting, a signal sounds to indicate that the system is shut down and restarted.
Blocking Webasto. This function is enabled if the error is repeated 4-6 times. When the device is locked, a report is saved. It is almost impossible to unlock the device yourself; it is recommended to contact the service center for this. It should be noted that the lock will not engage if the fault is caused by low voltage or battery failure.
Overheating lock
The device has shut down due to an error caused by low or high voltage. The device will temporarily shut down if the voltage reaches 11.5V. Then the blowdown is started. If the problem is resolved, the system can work again.

Other reasons for disabling Webasto are determined using the adapter for Webasto and Eberspacher diagnostics and the Thermo Test computer program.

To carry out a computer test of the heater, you will need Webasto diagnostic equipment. It includes a universal USB adapter K-Line (to line), a Webasto diagnostic program, as well as two wires with clips and one with a flat contact for connecting the adapter to the heater control bus.
The Webasto diagnostic adapter can be purchased from your specialist retailer. It is required to connect a computer via a USB port to the W-bus connector of the Webasto diagnostic control unit. The converter is designed to control the settings and functions of the car via a computer.
The Webasto Thermo Test (WTT) program allows you to test the operation of the heaters. WTT allows you to read information from the vehicle control unit, search for errors and start the device. You can download the WTT program on the official website of Webasto.
Before starting the diagnostics, it is necessary to select the connected heater from the list of equipment. The control unit selection opens after starting the program.

Webasto Thermo Test program

The Webasto Thermo Test (WTT) software supports almost all diagnosable heaters.

Diagnostics by Webasto K-line adapter is as follows:

Connect all three wires to the adapter on one side. The clips are attached to the battery. The third wire connects to the heater diagnostic wire, which is usually yellow.
Connect adapter to laptop via USB port. In this case, the operating system must itself install drivers for it. If this does not happen, then the drivers can be installed independently. They are included in the scope of delivery from the manufacturer.
Start the installed WTT program and select the model of the pre-heater in the start window.
Run diagnostics. All heater malfunctions will definitely be identified.
If the cause is not in the instrument itself, additional checking of the components is necessary. To do this, open the "Diagnostics / Component Test" section, mark the items to be checked and press "Start".

During all diagnostics, there is a continuous recording of processes with a time stamp. They can be saved and then played back using the functions in the Favorites tab in the WTT Session section. You may need this when contacting technical support for help. Therefore, after the end of the diagnostic procedure, it is imperative to complete the recording to save the results.
If the diagnostics and testing of Webasto found faults, you can contact error code table... If you hover the mouse cursor over the detected error in the list on the laptop screen, a short explanation with recommendations will appear.

The main thing to remember is that incorrect application of the program can lead to failure of the heater, leading to leakage or ignition of fuel. Therefore, for the diagnosis of such complex devices as Webasto, it is better to contact a specialist.

Video (click to play).