XSeries-forum

guys, i thought of getting my aux heater sorted out while its nice and warm out there (am i insane? naah i hope not ).

Hooked up the reslers unit to the webasto.

with the wiring all sorted i ran individual tests. all tests seem to go ok except for the glow plug test, which went  as below:
during the test:


and then the error log after the test:


i could immediately suspect the glow plug. before i find the way to discon the glow plug and test it is there anybody who's experienced this?

also, where can i source the parts, if anybody knows pls?
i suspect i will have to replace either the glow-plug, circuit board or both.

cheers

j

There are a few Webasto spares stockists....not many in the UK though.  Caravan/Boat spares suppliers may be able to assist.  Might be cheaper to get a second hand unit from the usual Austin sites?

found a couple of units online on ebay, like this one - bmw breakers really, costing about £250 for a full used unit. they say in working order and returnable if not.

reluctant to go that path, prefer to repair the unit by replacing the faulty comp. cos end of the day can't be sure of those either beyond a couple of months..

found this repairer as well. can talk to them and send the unit for repair. but agian no fun like doin it myself..  they sell parts as well. i will call them up and buy the part maybe.

so i'm lookin for parts suppliers, like the PCB, glow plug.

if anybody knows any sources for parts, let me know pls.

thx

j

Did a fuel-pump test today with the reslers.


does anyone know where the fuel pump is located and how to access it?



discon the fuel pump and ran the test with a measuring cup on the fuel line. hardly any fuel came through, although it should have pumped 20ml in a one minute test window. i could hear a pulsating/knocking sound from under the car for a few secs and then it stopped. drips of fuel came out during this period.

so although the fault list indicated a glow-plug/flame-detector issue, i now suspect that the issue is possibly no fuel coming through? possibly there's no sensor to indicate that to the test sw so it just gives a generic error - glow-plug/flame-detector.

so now i need to access the fuel pump and check that out, if necessary get a replacement unit and see if that works.

cheers

j

Service Manual might help you identify if the part is separate or part of a 'block' or module that has to be completely replaced.

Google 'Webasto Thermo Top Z parts' and you'll get a number of spares suppliers......

thx, i have that. The 'dosing pump' indicated there is what i'm looking for. i think its under the car.

undeside of the car is fully covered with panels. i need to figure out how to remove the panels and how to identify and access the pump.


EDIT
found it, thisis what i was lookin for!

now i need to find exactly where it is. the bottom panels also come out easy i think..

Have a look at the copy of the TIS linked to on this site......it's in the 'General Discussion' section..

Might be instructions on how to remove things buried in there.....

yeah - been lookin in there for about an hr now..

not much luck so far..

if anybody knows where the aux heater fuel pump is and how to access pls let me know.

i'm gonna go looking for it next time i have some time.. under the car.

i have olympics tickets for tomorrow so tomorrow is out 

j

SORTED!

finally, i have my webasto working! with a lot of help from this forum, with diagnostics from the scanner, the restlers, plus some help from some very experienced members here on pm  :beer2:

i can possibly write a book on this subject now, incl diagnostics, removal and service. just one last chapter to workout before i actually do a writeup - how to get a busted webasto  PCB repaired - that's now WIP with a spare PCB with a contact i've found in Germany!

last but not the least, the remote start now. given the effort i've put in to this i thought of going for the 'real deal' - the GSM based remote kit.

i've found this, seems decent.

does anybody know any other GSM based remotes pls?

thx

J

Wow can't wait for the write up as mine doesn't work (

Can anyone help me enable my heater for interior heating on our 2005 3.0D E53 X5

I have enabled the OBC computer for the timers and direct heating.

I fitted a brand new heavy duty battery yesterday

I have only managed to get the heater running for a few minutes, sometimes with cold air coming from exhaust, sometimes nothing coming from exhaust.

If I apply power to pin 1, what is the best way to do it without damaging or cutting anything?

Where is the other end of the wire that normally resides in pin 1? - telestart plug in the boot? Can I anyone confirm that there is no way 12v can arrive at pin 1 from the already fitted wire as well as a remote tapped into it - effectivly ending up with 24v and a dead component.

My unit is labelled thermotop z on the front, and thermotop c on the side.

The water pump appears to between the n/s/f headlight and ABS pump

I have an unused 2 pin plug located under the heater (grey/black wire & a black/red wire) - does this grey wire go to pin 2 on the Climate Control panel? Whats it for?

My Climate Control panel is part number 64116972163

Any help appreciated.

[quote="Alan703"]
Can I anyone confirm that there is no way 12v can arrive at pin 1 from the already fitted wire as well as a remote tapped into it - effectivly ending up with 24v and a dead component.[/quote]

You certainly can't generate 24V when you only have a 12V vehicle.  That needs two batteries in series - which you don't have so that's nothing to worry about.  Unless you were planning to add another external power supply of course - don't!

The way I tested mine was to stick a sewing needle down the side of Pin 1 until I got a got connection, and then just ran a thin piece of wire with a croc clip on each end to the +12V jump start point.  If you want, you can make up a lead with a 5A (or less) fuse in line for testing purposes.

Richard

[quote="Alan703"]

I have only managed to get the heater running for a few minutes, sometimes with cold air coming from exhaust, sometimes nothing coming from exhaust.

[/quote]

i had this problem initially. cold air on the exhaust means webo tries to start. but not firing up. possibilities, in the order i suspect:
1. faulty glow plug
2. faulty pcb
3. no fuel

[quote="Alan703"]
If I apply power to pin 1, what is the best way to do it without damaging or cutting anything?
[/quote]

i would strip out a bit of insulation and make a solid connection. others have poked a sewing needle in.

in any case webo in stand by mode does a check for power on pin one in 30sec cycles. so make sure u hold a 12v supply for longer than that for the webo to start.

Also webo doesn't like power to pin 1 being disrupted. this is because it communicates on the k-bus during the start-up sequence and that gets interrupted. so it is not recommended to remove power in an ad-hoc fashion as in a rare case it can register a k-bus fault and record a lock-out status. if that happens the fault needs clearing.

webo service manual recommends power to pin 1 being a minimum of 3 minutes - which is the duration of the full start-up sequence.
[/quote]

[quote="Alan703"]
Where is the other end of the wire that normally resides in pin 1? - telestart plug in the boot?
[/quote]

Yes, i believe so.

[quote="Alan703"]
Can I anyone confirm that there is no way 12v can arrive at pin 1 from the already fitted wire as well as a remote tapped into it - effectivly ending up with 24v and a dead component.
[/quote]

as said, absolutely no chance.

[quote="Alan703"]
My unit is labelled thermotop z on the front, and thermotop c on the side.
[/quote]

that's standard. Thermotop Z is the generic webo model; the automotive variant is also labeled Thermotop C

[quote="Alan703"]
The water pump appears to between the n/s/f headlight and ABS pump
[/quote]

correct

[quote="Alan703"]
I have an unused 2 pin plug located under the heater (grey/black wire & a black/red wire) - does this grey wire go to pin 2 on the Climate Control panel? Whats it for?
[/quote]

don't know. not sure if we're talking about the same plug but i have an unused plug as well, in the wiring harness under the webo. not even sure if it has anything to do with the webo.

one thought actually. i think the US versions which originally came with parking heater option had different plumbing to enable only the car interior to be heated in the 'parking heater' mode; as opposed to heating the entire coolant network. maybe that plug was to drive some valve in the plumbing for that purpose.


hope that helps:)

Thanks for the guidance.

Am I right in saying if it locks out - start engine, remove fuse 59 for 10 sec + and reinsert.  I have no software to check stuff with.

I checked the glow plug resistance which came back at 0.00, i understand that is good, although the wires look quite brown towards the glow plug side.  I assume it could still be bunged up inside though? I can't see inside without removing it which I don't have time to do just now, especially as it means no car when it's off.

I bridged the telestart 12v and signal wire in the boot, something whirred up in the boot, then shut down.  The heater did sfa.

I think I've read all 31 pages, I remember reading something about newer cars missing stuff. Was that right.

[quote="Alan703"]
Am I right in saying if it locks out - start engine, remove fuse 59 for 10 sec + and reinsert.  I have no software to check stuff with.
[/quote]

never heard of that before. unlikely. both car and webo have fault memories. none get cleared by removing a fuse! you need tools and s/w to clear them. haven't read this method anywhere either.


[quote="Alan703"]
I checked the glow plug resistance which came back at 0.00, i understand that is good,
[/quote]

0.00 is not good. glow plug resistance should be between  0.245 and 0.325ohms

[quote="Alan703"]
I bridged the telestart 12v and signal wire in the boot, something whirred up in the boot, then shut down.  [/quote]

i don't have the standard telestart kit bit i wouldnt expect a 'whirring' noise from it. it should be just a solid state device with max a relay in it.

[quote="Alan703"]
I think I've read all 31 pages, I remember reading something about newer cars missing stuff. Was that right
[/quote]

no idea. don't think so. lots have got this done.

if your glow plug is showing 0.0ohms that might be the fault.. certainly not right.

j