Webasto install HDJ81

[IanB]

I've been having to park outside until my car goes to its new home at the end of the week, the Webasto has been amazing on these chilly mornings! I REALLY need to get the digital timer hooked up though, having to walk outside in my housecoat to flip the toggle switch is amateur hour stuff. I've been turning it on when I get in to drive home as well, and just running it to assist getting the engine up to temp while I drive home, works great for this as well! Once the timer is in I'll just set it to come on an hour before I leave, can't wait!

 

[oszkari]

Agreed, Webasto is great investment. it's a day and night difference when it comes to cold start.

 

[franklin40]

yesterday was the first time i used mine too. came in from a flight and straight away i had warm air blowing and the engine was happy to be running even after being outside for 3 days. great accessory to have. i’m still interested in figuring out a smart phone activated relay.

 

[oszkari]

yesterday was the first time i used mine too. came in from a flight and straight away i had warm air blowing and the engine was happy to be running even after being outside for 3 days. great accessory to have. i’m still interested in figuring out a smart phone activated relay.

CDMA is cool because you don't have any distance limitation but I guess you would need to pay for a plan to keep the SIM card going.
I'm thinking to try out the 2.4Ghz or 5.8Ghz WIFI relays that come with an App for smartphones.

 

[IanB]

So I got off my ass and wired in the digital timer...not sure what took me so long, this thing is GREAT! Still need to wire it into the command start to be triggered off the trunk release, no ETA on that one, lol. See ya later toggle switch!

 

[IanB]

Got back off my ass and got the digital timer wired to my command start trunk button. Negative pulse to pin 7 and the timer turns on as if you'd hit the button on the timer, runs for whatever cycle time you have it programmed for, and the engine is warm when you make it out to start it, amazing.

 

[franklin40]

i’ve been using my timer a bunch this year. we’ve had three weeks of minus 40 and my 1hdt startslike a champ with very little rough idle. i think i want to move where it sits in the engine compartment though. the hose length is too long to the block and i bet i loose a ton of heat before it even gets inside the block

 

[oszkari]

I started to have issues with my webasto heater. Once turned on runs a few minutes then the pump stops ticking, no exhaust gas and all i can hear is just a quiet base sound.

Voltage is 12.5v, fuel filter is visibly full.

What i noticed was that the coolant hose that goes into the cabin from webasto is hot, but the return line from the cabin to engine is cold.

If i turn the engine on, shortly the webasto comes back alive, the fuel pump starts to tick and i have got exhaust gas again.

The cruiser cabin heating unit was at HI and full heat all time. Seamingly the unit works ok I can adjust temperature with the slider and the blower from low to hi.

Im not sure how turning the engine on is influencing the coolant flow trough the cabin radiator but right now my best guess is that somehow when the engine is turned off the coolant liquid passage is blocked. Once the coolant temp reaches 72c on that short section between webasto and cabin, webasto goes standby.

My second guess is that the webasto coolant pump died and it is unnable to push the fluid by itself.

Any ideas? Does my theory make any sense?

Everything worked just fine and suddenly stopped working. The only thing that changed was the ambient temperature, increased from -30c to + 2c.

Thank you!

 

[cruiserpilot]

^^Cullens Diesel in Vancouver/or Langley is the local dealer/service center. I shipped mine to them from the island for a
service. If it's in the truck they can plug in to it for a diagnostic check.

 

[efjay6tee]

Is your coolant level low?

 

[lumpy70]

Webastos only stop working for 3 reasons: no electricity (or too low), no fuel, or no coolant flow.

In 16 years and 3 truck installs I'd say that the first thing (9/10 times) is low voltage. This will cause the unit to try to run for 3 minutes and do a 3 minute shutdown. I'd check voltage on the unit right at the unit harness) the whole cycle. There is a simple procedure to clear that code (I'll have to look it up). I have good batteries and is running off of an aux source but idling my way to work on a cold day for 20 minutes isn't enough to charge the auxiliary battery. When I'm using it regularly I plug a charger into the battery every night. Doing that, it hasn't failed me.

The only other problem I've seen is air bubbles in the coolant line. In the big rigs these are installed on the frame rails, and the manual says "as low as possible in the coolant system"...but cruiserheads want things up high so they don't get damaged. Try cracking your rad cap (safely) when truck is at operating temperature a few times to bleed air, or install lower (which sucks). If the unit feels like there is no coolant flow it will shut down.

Hope some of that helps

 

[lumpy70]

My phone isn't letting me post the link, but google: "webasto low voltage lock out reset" I believe the link is the 2nd one (pdf) and the procedure is on page 3

The fuse they are referring to is at the harness or unit, not your cruiser fuse.

 

[coldtaco]

I started to have issues with my webasto heater. Once turned on runs a few minutes then the pump stops ticking, no exhaust gas and all i can hear is just a quiet base sound.

Voltage is 12.5v, fuel filter is visibly full.

What i noticed was that the coolant hose that goes into the cabin from webasto is hot, but the return line from the cabin to engine is cold.

If i turn the engine on, shortly the webasto comes back alive, the fuel pump starts to tick and i have got exhaust gas again.

The cruiser cabin heating unit was at HI and full heat all time. Seamingly the unit works ok I can adjust temperature with the slider and the blower from low to hi.

Im not sure how turning the engine on is influencing the coolant flow trough the cabin radiator but right now my best guess is that somehow when the engine is turned off the coolant liquid passage is blocked. Once the coolant temp reaches 72c on that short section between webasto and cabin, webasto goes standby.

My second guess is that the webasto coolant pump died and it is unnable to push the fluid by itself.

Any ideas? Does my theory make any sense?

Everything worked just fine and suddenly stopped working. The only thing that changed was the ambient temperature, increased from -30c to + 2c.

Thank you!

low coolant or built in water pump failing?

 

[oszkari]

Thanks for the replies! I did some further troubleshooting today and looks like the Webasto water pump has died. I will get a replacement pump from the dealer and hopefully everything goes back to normal.

 

[cruiserpilot]

Be ready, these parts are not inexpensive. If you get it apart send a pic of the
old pump, I'd be curious to see it.

 

[IanB]

Thanks for the replies! I did some further troubleshooting today and looks like the Webasto water pump has died. I will get a replacement pump from the dealer and hopefully everything goes back to normal.

This might sounds silly, but make sure you've got it plumbed so the webasto flows the same direction as the truck's coolant system. If the webasto is running with the engine and it's fighting the coolant flow, it won't last long.

 

[dan1554]

I used one of these and it is physically a match for the pump location on the webasto, and the input/output are in the right locations. Even the bracket strap it came with fits the webasto. I would not be surprised if it was the same thing. Might have to find a new power connector though. Do your own research first, of course. Just another possibility.

NEW FORD MONDEO MK4 GALAXY S-MAX VOLVO S60 S80 V60 V70 XC60 XC70 WATER PUMP ASSY | eBay

 

[cruiserpilot]

I used one of these and it is physically a match for the pump location on the webasto, and the input/output are in the right locations. Even the bracket strap it came with fits the webasto. I would not be surprised if it was the same thing. Might have to find a new power connector though. Do your own research first, of course. Just another possibility.

NEW FORD MONDEO MK4 GALAXY S-MAX VOLVO S60 S80 V60 V70 XC60 XC70 WATER PUMP ASSY | eBay

You actually repaired your Webasto with this? how old is your Webasto and which model is it?

 

[dan1554]

I cobbled my whole setup together from a bare unit. Here's a link to that post with a picture of the pump attached:
Webasto install HDJ81

Nameplate is attached to this post.

 

[oszkari]

This might sounds silly, but make sure you've got it plumbed so the webasto flows the same direction as the truck's coolant system. If the webasto is running with the engine and it's fighting the coolant flow, it won't last long.

You got me thinking for a second, but I double checked It and I think i'm good. Coolant flow: Engine -> IN Webasto OUT -> Cabin.

I have installed the new water pump and everything works again. The new pump it's a bit louder than the previous one, not sure if it's good or bad..