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Webasto Thermo 90 Workshop Manual
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Thermo 90
8 Servicing
803
NOTE
Manufacturer mo
unts co
nt
rol unit of
heaters Therm
o 90 S to c
o
mbustion
air fan.
With C
h
eck V
alv
e and Thermostat
Without Check Valv
e
1
Heat
Exchanger,
Vehicle Heating System
2
Blower Switch
Vehicle Heating System
3
Relay for Vehicle Blower
4T
i
m
e
r
5
Fuse Box in Vehicle
6
Check Valve with Drain
Hole
7
T-J
unction
8
Vehicle Engine
9
Heater
Unit
10
Circulation Pump
11
Water Pump
12
Radiator
13
Regulating Valve
14
Control Unit
15
Exhaust Muffler
16
Dosing Pump
17
Combustion Air Intake Line
18
Thermostat
Cable Loom
Fuel Line
Exhaust Line
Coolant Circuit
34
36
Table of Contents
List of
2
Default Chapter
2
Table of Contents
2
General
2
Adjustment of the CO Contents
3
Adjustments
3
Combustion Air Fan Test
3
Components Testing
3
Flame Sensor Resistance Test
3
Functional Tests
3
Glow Plug Resistance Test
3
Temperature Sensor Resistance Check
3
1 Introduction
6
Note
6
Caution
6
Introduction 1.1 Scope and Purpose
6
Meaning of Warnings, Cautions, and Notes
6
Additional Documentation to be Used
6
Safety Information and Regulations
6
General Safety Notes
6
Legal Provisions for Installation
7
Corrections and Improvements
8
Heat Exchanger
10
Temperature Sensor
10
Temperature Limiter
10
Burner Insert
10
Glow Plug
10
2 General Description
11
Combustion Tube
12
Circulation Pump
12
Control Unit
12
Flame Sensor
12
3 Troubleshooting
14
Heating Operation
14
Control Operation
14
Switch-Off
15
Malfunctions
16
Switch-Off Upon Failure
16
Diagnosis after Switch-Off Upon Failure (Thermo 90)
16
4 Technical Data
19
5 Troubleshooting
21
Troubleshooting 5.1 General
21
General Failure Symptoms
21
Failure Symptoms after Switch-Off Upon Failure
22
Visual Inspection for Assessment of Burner Condition
23
Burner Housing
23
Rear Wall with Metal Evaporator
24
Combustion Chamber
24
Burner Assembly
24
6 Functional Tests
25
Circuit Diagrams 7.1 General
27
Combustion Air Fan (See 9.2.5)
27
Circuit Diagrams
28
Servicing 8.1 General
33
Work on the Heater
33
Work on the Vehicle
33
Heater Test Run
34
Servicing
34
Note
35
Connection to the Vehicle's Cooling System
36
Connection to the Vehicle's Fuel System
36
Visual Inspections and Installation Regulations
36
Dosing Pump
38
Combustion Air Supply
39
Exhaust Line
39
Fuel Filter
39
Heater, Removal and Installation
40
Removal and Installation
40
Replacement of Circulation Pump
40
Replacement of Temperature Limiter
40
Replacement of Temperature Sensor
40
Repair 9.1 General
42
Work on Components after Disassembly
42
Disassembly and Assembly
43
Electrical Connections
43
Replacement of Circulation Pump
44
Replacement of Temperature Limiter
45
Replacement of Temperature Sensor
45
Replacement of Combustion Air Fan
47
Replacement of Burner, Flame Sensor, and Glow Plug
48
Replacement of Burner Head
50
Replacement of Heat Exchanger
51
Packaging/Storage and Shipping 10.1 General
52
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Webasto Thermo 90 Specifications
General
Brand
Webasto
Model
Thermo 90
Category
Water Heater
Language
English
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