Coolant Heater

Thermo 90 ST D (Diesel)
Thermo 90 ST B (Gasoline)
Service and Repair Manual

 While a Webasto heater is in use, the product surface, connected hoses,

ducting and air outlet(s) may become hot to the touch. Contact with skin may cause
burns.
 Improper installation or repair of Webasto heating systems can cause fire or
the leakage of deadly carbon monoxide leading to serious injury or death.
 NEVER attempt to install or repair a Webasto heating system unless you have
successfully completed Webasto factory training and have the technical skills, technical
information, tools and equipment required to properly complete the necessary
procedures. Only genuine Webasto parts may be used.
 Webasto rejects any liability for problems and damage caused by the system
being installed by untrained personnel.
 Webasto products produce temperatures high enough to ignite surrounding
combustible materials such as inflammable liquids, gases, vapor, and other combustible
matter. The heater must be switched off when loading or unloading inflammable
materials to prevent the risk of explosion.
 ALWAYS and carefully follow Webasto installation and repair instructions and
heed all WARNINGS.
THERMO 90 ST TABLE OF CONTENTS

Contents Page

1. Introduction 1
1.1 Contents and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Meaning of Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Additional Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Safety Information and Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4.1 General Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.5 Suggestions for Improvements and Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. General Description 3
2.1 Combustion Air Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Temperature Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Burner Insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.6 Glow Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Flame Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.8 Combustion Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.9 Circulating Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.10 Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.11 Metering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Functional Description 7
3.1 Switching On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Heating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Switching Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5.1 Fault Lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5.2 Diagnosis after Fault Lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Technical Data 11
5. Troubleshooting 13
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 General Fault Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Fault Indications on Fault Lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4 Visual Check for Assessing the Burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6. Functional Tests 19
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2.1 Setting the CO2 Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.3 Testing Individual Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.3.1 Resistance Test of the Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.3.2 Resistance Test of the Ceramic Glow Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.3.3 Resistance Test on the Flame Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.3.4 Testing the Combustion Air Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7. Circuit Diagrams 21
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.2 Thermo 90 ST Circuit Diagram Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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8. Servicing Work 25
8.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
8.2 Work on the Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
8.3 Work on the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
8.4 Heater Trial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
8.5 Service Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
8.6 Visual Inspections and Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.6.1 Connection to the Vehicle Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.6.2 Connection to the Vehicle Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.6.2.1 Fuel Extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
8.6.2.2 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
8.6.3 Fuel Metering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
8.6.3.1 Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
8.6.3.2 Installation and Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.6.4 Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.6.5 Combustion Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.6.6 Exhaust Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.7 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.7.1 Heater, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.7.1.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.7.1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.7.2 Changing the Circulating Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.7.3 Changing the Temperature Limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.7.4 Changing the Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.7.5 Changing the Combustion Air Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.8 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9. Repair 37
9.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.1.1 Work on Stripped-down Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.1.1.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.1.1.2 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.2 Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.2.1 Replacing the Circulating Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.2.1.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.2.1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.2.2 Replacing the Temperature Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
9.2.2.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
9.2.2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
9.2.3 Replacing the Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
9.2.3.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
9.2.3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
9.2.4 Replacing the Combustion Air Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
9.2.4.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
9.2.4.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
9.2.5 Replacing the Burner, Flame Monitor and Glow Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
9.2.5.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
9.2.5.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
9.2.6 Replacing the Burner Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
9.2.6.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
9.2.6.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
9.2.7 Replacing the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

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9.2.7.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2.7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10.Product Information 47

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THERMO 90 ST INTRODUCTION

1. INTRODUCTION 1.4.1 GENERAL SAFETY REGULATIONS

The year of first start-up must be indelibly
1.1 CONTENTS AND PURPOSE identified on the rating plate by removing the
corresponding year number.
This repair shop manual is intended to assist trained
personnel with repairing both the gasoline and the diesel The heaters are only licensed for heating the motor
versions of the Thermo 90 ST water heaters. vehicle engine and vehicle cabin, not however for
heating hazardous material transport space.
1.2 MEANING OF SIGNAL WORDS The heater is only allowed to be installed in motor
vehicles or in independent heating systems with a
Throughout this manual, the signal words DANGER, minimum coolant volume of 6 liters (6.34 quarts).
WARNING, CAUTION, and NOTE have the following The heater is not allowed to be installed in the driver’s
meanings: cab or passenger compartment of vehicles. If the heater
is nevertheless installed in such a place, the installation
DANGER: This heading and text style is box must be tightly sealed against the vehicle interior.
used to highlight that non-compliance with The installation box must have sufficient external
instructions or procedures will cause ventilation to ensure that a maximum temperature of
injuries or lethal accidents to personnel. 40 °C (104 °F) is not exceeded in the box. Malfunctions
may occur if the temperature exceeds this level.
WARNING: This heading and text style is
used to highlight that non-compliance with WARNING: The heater must not be
instructions or procedures may cause operated in enclosed areas, such as garages
injuries or lethal accidents to personnel. or workshops without an exhaust
emissions extraction system, not even
CAUTION: This heading and text style is using the timer or Telestart, because of the
used to highlight that non-compliance with risk of asphyxiation and poisoning.
instructions or procedures may cause
damage to equipment. WARNING: Webasto heaters must be
switched “off” when re-fueling at filling
NOTE: This heading and text style is used to stations and/or while loading or unloading
highlight and draw attention to information we flammable materials for transport, to
feel you would like to have. It could have to do prevent the risk of explosion. Please
with procedures and tips that will help you work review owner’s manual for safety and use
more efficiently. instructions.

1.3 ADDITIONAL DOCUMENTATION CAUTION: Wherever inflammable vapors

or dust may form (for example near fuel,
This workshop manual contains all the information and coal, wood dust or cereal stores or the like),
instructions required for repairing Thermo 90 ST water the heater must be switched off because of
heaters. Normally, there is no need to use additional the risk of explosion.
documentation. If required, the installation instructions,
the vehicle-specific installation instructions and the A temperature of 85 °C (185 °F) (storage temperature)
operating instructions can be used as well. must not be exceeded in the vicinity of the control unit
(for example when completing painting work on the
1.4 SAFETY INFORMATION AND REGULATIONS vehicle).
If this temperature is exceeded, the electronic systems
In principle, the general accident prevention regulations may suffer permanent damage.
and current works safety instructions are applicable.
Follow the instructions supplied by the vehicle
The “General safety regulations” that go beyond the
manufacturer to check the cooling water level. The
scope of the above regulations are stated below.
water in the heating circuit of the heater must contain at
Any special safety regulations relevant to this instruction least 10% branded anti-freeze.
manual will be highlighted in the relevant sections or text Non-compliance with the installation instructions and the
passages of the procedures. warnings contained therein will lead to the exclusion of
all liability by Webasto. The same applies if repairs are

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INTRODUCTION THERMO 90 ST

carried out incorrectly or with the use of parts other than

genuine spare parts. This will result in the revocation of
the type license for the heater and therefore the general
operating license for the vehicle.

1.5 SUGGESTIONS FOR IMPROVEMENTS AND

CHANGES

Complaints, improvement suggestions or corrections

relating to this workshop manual should be addressed to:

Webasto Thermo & Comfort N.A., Inc.

Technical Documentation Group
15083 North Road
Fenton MI 48430
Phone: 810.593.6000 PC-Fax: 810.593.6135

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THERMO 90 ST GENERAL DESCRIPTION

2. GENERAL DESCRIPTION Thermo 90 ST heater is principally composed of

– the combustion air fan
Thermo 90 ST water heaters operate in conjunction with – the heat exchanger
the vehicle’s own heating system and serve
– the burner insert with combustion pipe
– to heat the cab,
– the circulating pump
– to defrost the vehicle windows and
– to preheat water-cooled engines.
To control and monitor it, the heater has
– a control unit (external)
The water heater operates independently of the engine
and is connected to the cooling system, the fuel system – a flame monitor
and the electrical system of the vehicle. – a glow pin
The concept of the heater is based on the evaporator – a temperature sensor
principle. It is controlled by the temperature sensor and – a temperature limiter
operates intermittently.
inside it.
Depending on the deviation between the current coolant
temperature and the nominal value measured at the
temperature sensor, the burner power is regulated The Thermo 90 ST heater is delivered with the control
between the limits of 1.8 to 7.6 kW in diesel heaters and unit already flange-mounted on the combustion air fan.
2.0 to 7.6 kW in gasoline heaters. When the heating
requirement is particularly high (preheating), diesel
heaters provide a maximum power of 9.1 kW for up to The fuel supply is provided from an external source using
2 hours after the heater is switched on. a metering pump.

4
1 2 3

1 Combustion air fan

2 Fuel connection
3 Temperature sensor
4 Temperature limiter
5 Heat exchanger
6 Inlet, coolant
7 Circulating pump
8 Outlet, coolant
9 Outlet, exhaust gas
11 10 9 8 7 10 Inlet, combustion air
11 Control unit
Figure 1: Thermo 90 ST heater

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GENERAL DESCRIPTION THERMO 90 ST

2.1 COMBUSTION AIR FAN 2.3 TEMPERATURE SENSOR

The combustion air fan supplies the air required for the The temperature sensor records the coolant temperature
combustion process from the combustion air inlet to the at the coolant outlet of the heater as an electrical
burner insert. resistance. This signal is fed to the control unit where it is
processed.

2.4 TEMPERATURE LIMITER

The overheat guard circuit (bimetallic) protects the heater

against impermissibly high operating temperatures.
The overheat guard circuit trips if the heat exchanger
temperature exceeds 127 ±7 °C (260.6 ±10 °F) and
switches off the heater. This is a self resetting switch.

2.5 BURNER INSERT

The fuel is distributed over the burner cross-section in the

combustion pipe in the burner insert.

2.6 GLOW PIN

The mixture of fuel and air is ignited by the glow pin

when the heater is started. The glow pin takes the form
Figure 2: Combustion air fan of an electrical resistor and is positioned in the burner
insert on the side away from the flame.
2.2 HEAT EXCHANGER
Glow Pin Burner Insert
In the heat exchanger, the heat generated by combustion
is transferred to the coolant circuit.

Temperature Limiter

Temperature Sensor

Flame Monitor

Figure 4: Burner Assembly

2.7 FLAME MONITOR

The flame monitor is a low-ohm PTC resistor, which

changes its resistance depending on the heat emitted by
the flame. The signals are fed to the control unit where
Figure 3: Heat exchanger they are processed. The flame status is monitored by the
flame monitor whenever the heater is operating.

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THERMO 90 ST GENERAL DESCRIPTION

2.8 COMBUSTION PIPE 2.10 CONTROL UNIT

The mixture of fuel and air burns in the combustion pipe, The control unit is the central component. It guarantees
thus causing the heat exchanger to become hot. the sequence of functions and monitoring of combustion
mode. It is flange-mounted on the combustion air fan.

Figure 5: Combustion pipe

Figure 7: Control unit - flange mounted

2.9 CIRCULATING PUMP

The circulating pump ensures that coolant is pumped 2.11 METERING PUMP
through the vehicle and heater circuits. The pump is
switched on by the control unit and it runs throughout The fuel supply and metering for the heater is assured by
operation of the heater (including in the control pause). an external metering pump. In addition, it serves as a
shut-off element when the heater is switched off.
The solenoid coil of the metering pump receives its pulses
from the microprocessor in the control unit.

0-90° 0-90°
0°

Figure 8: Fuel metering pump

Figure 6: Circulating pump

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GENERAL DESCRIPTION THERMO 90 ST

This page for your notes.

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THERMO 90 ST FUNCTIONAL DESCRIPTION

3. FUNCTIONAL DESCRIPTION
3.1 SWITCHING ON
Diesel Heaters
The “operating indicator” on the digital timer lights up If the water temperature in the heater is higher than the
when the “immediate heating” button is pressed. nominal temperature but has not yet reached the
or threshold for the control pause and if the temperature
then falls back to the nominal temperature within 10
When switching on with the switch, the operating minutes (after reaching this temperature for the first
indicator in the switch lights up. time), the heater switches back to the 9.0 kW heating
The circulating pump, glow pin and combustion air fan stage.
start operating. When the nominal temperature is reached, the heater is
only switched back on again up to the 7.6 kW heating
3.2 HEATING MODE stage.

Gasoline Heaters
Combustion starts after approx. 60 to 140 seconds.
Automatically controlled heating operation runs at full The maximum heating power in gasoline heaters is
load for a maximum of 2 hours. always 7.6 kW.
The vehicle’s own heater fan does not switch on until the
heat carrier (coolant) has heated up sufficiently. Once
the preset nominal temperature has been reached (see 3.4 SWITCHING OFF
table of regulating temperatures) the heating power is
reduced to the lowest part load in small individual steps.
The operating indicator on the digital timer/switch goes
out when the heater is switched off. The combustion
3.3 CONTROL MODE process will be ended and the run-on phase will start.
The circulating pump and the combustion air fan
The heater switches to the control pause if the
continue to run, however, in order to cool down the
temperature of the coolant continues to rise to the
heater (run-on) and are switched off automatically after
threshold of the control pause. The circulating pump,
approx. 105 seconds. The heater may be switched on
the vehicle’s own heater fan and the operating indicator
again during the run-on time.
continue to operate during the control pause.
The temperature in the cabin can also be controlled using
The heater restarts when the coolant cools to the preset
the vehicle’s own heater fan with a cabin thermostat.
temperature for switching back on.

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FUNCTIONAL DESCRIPTION THERMO 90 ST

2 5 7 12 15 18 22

1 3 4 6 8 9 10 11 13 14 16 17 19 20 21 23

1
A 0
1
B 1 4
/
0
1
1 2
/
C 1
/4
0
1 * *If no flame is formed,
D 0 the start is automatically
1 repeated (20 s pulse pre-
E 0
glow, 90 s safety time).
1
F 0
1
G 0

30 80 90 75 70 °C

Safety time

Figure 9: Sequence of functions

Sequence of functions for Thermo 90 ST

A. Glow pin
B. Metering pump
C. Combustion air fan
D. Flame monitor
E. Operation indicator light
F. Circulating pump
G. Vehicle fan

1 Switch on 13 Run-on ended (cool-down)

2 Component interrogation 14 Pre-glow 15 – 20 s (pulsed)
3 Pre-glow 40 s (pulsed) 15 Metering pump supply 5 – 7 s (1)
4 Metering pump supply 5 – 7 s (1) 16 Metering pump / part load (1/4)
5 Metering pump / part load (1/4) 17 Flame monitor take-over
6 Flame monitor take-over 18 Stabilization time
7 Stabilization time 19 Coolant temperature reduced
8 Full load 20 Full load
9 Vehicle fan “On” 21 Switch off (run-on)
10 Control range 22 Flame monitor “Cold” (0)
11 Control pause 23 Run-on ended (cool-down)
12 Flame monitor “Cold” (0)

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THERMO 90 ST FUNCTIONAL DESCRIPTION

3.5 MALFUNCTIONS
F 01 No start (after 2 attempts to start)
3.5.1 FAULT LOCK-OUT F 02 Flame failure
F 03 Under voltage or over voltage
Fuel is supplied for max. 240 seconds if the flame does F 04 Premature flame recognition
not start to burn. F 05 Flame monitor interrupt or flame monitor
Fuel is supplied for max. 240 seconds if the flame goes short circuit
out during operation. F 06 Temperature sensor interrupt or temperature
sensor short circuit
The fuel supply is shut off if the system overheats F 07 Metering pump interrupt or metering pump
(temperature limiter is tripped). If the system overheats short circuit
the temperature limiter will reset itself after cool down F 08 Fan motor interrupt or fan motor short circuit
period. or fan motor incorrect speed
Once the cause of the fault has been eliminated, the F 09 Glow pin interrupt or glow pin short circuit
fault lock-out is canceled by following the heater lockout F 10 Overheating
procedure steps below: F 11 Circulating pump interrupt or circulating
pump short circuit
1. Using switch or standard timer control, turn heater
on
3.5.2.2 VERSION WITH SWITCH
2. Remove the main power connection to heater from
battery or pull fuse for a minimum of 20 seconds. If the system is operated with a switch, the nature of the
fault is indicated by a flashing code on an operating
3. Using switch or standard timer control, turn the indicator light during the run-on time of the heater.
heater off.
4. Reinstall main heater power connection where
previously disconnected. After five short signals, count the long flashes:
1x No start (after 2 attempts to start)
Rectify the cause of the fault. 2x Flame failure
3x Under voltage or over voltage
4x Premature flame recognition
IMPORTANT: Heater fault codes can be read using PC 5x Flame monitor interrupt or flame monitor
Diagnostics, however, the heater lockout reset must be short circuit
manually performed using the procedure stated above. 6x Temperature sensor interrupt or temperature
sensor short circuit
7x Metering pump interrupt or metering pump
If the under voltage protection switches off the system
short circuit
for longer than 20 seconds, the fuel supply is interrupted
8x Fan motor interrupt or fan motor short circuit
and the heater is shut off. (see table below).
or fan motor incorrect speed
9x Glow pin interrupt or glow pin short circuit
Thermo 90 ST 10x Overheating
12 volts 10.5 V - 0.5 V 11x Circulating pump interrupt or circulating
pump short circuit
24 volts 21 V -1 V

CAUTION: A forced reset of the return

spring when hot can result in damage to
the component.

3.5.2 DIAGNOSIS AFTER FAULT LOCK-OUT

Check the fuses and plug connectors.

3.5.2.1 VERSION WITH DIGITAL TIMER

If the system is equipped with a standard timer, a fault
message appears on the display of the digital timer after
a fault occurs:

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FUNCTIONAL DESCRIPTION THERMO 90 ST

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FUNCTIONAL DESCRIPTION THERMO 90 ST

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FUNCTIONAL DESCRIPTION THERMO 90 ST

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THERMO 90 ST TECHNICAL DATA

4. TECHNICAL DATA Fuel for Thermo 90 ST B (gasoline):

The fuel specified by the manufacturer must be used.
Except where limit values are specified, the technical data
listed in the table refer to the usual heater tolerances of Fuel for Thermo 90 ST D (diesel/PME):
±10% at an ambient temperature of +20 °C (+68 °F) and The diesel fuel specified by the vehicle manufacturer
at the rated voltage and in rated conditions. must be used.
Electrical components: We know of no negative influences due to additives.
The control unit, motors for combustion air fan and If fuel is extracted from the vehicle’s tank, follow the
circulating pump, ceramic glow pin, metering pump, additive instructions issued by the vehicle manufacturer.
timer, and switch are designed for 12 V or 24 V. If you change to low-temperature fuel, the heater must
The temperature limiter, temperature sensor and flame be operated for approx. 15 minutes so that the fuel
monitor are identical on 12 V and 24 V heaters. system is filled with the new fuel.
The Thermo 90 ST D heater is also licensed for use with
PME (bio-diesel), which complies with ASTM D6751 and
DIN EN 14214.

HEATER Operation THERMO 90 ST B THERMO 90 ST D

EC licensing symbol ~S299 ~S298
Model Water heater with Ferro-Tec Burner
Heat Output Boost max. N/A 9.1 kW (31078 BTU/h)
Regulating 2.0 kW – 7.6 kW 1.8 kW – 7.6 kW
range (6830 – 25955 BTU/h) (6147 – 25955 BTU/h)
Fuel Gasoline Diesel #1, #2, Arctic, PME and
Kerosene
Fuel Consumption Boost max. N/A 1.1 l/h (0.29 g/h)
Regulating 0.25 l/h – 1.0 l/h 0.19 l/h – 0.9 l/h
range (0.066 g/h – 0.264 g/h) (0.05 g/h – 0.24 g/h)
Rated Voltage 12 V 12 V 24 V
Operating Voltage Range V 10 – 15 V 10 – 15 V 20 – 30 V
Nominal power consumption with Boost max. N/A 90 W
circulating pump Regulating 37 W – 83 W 37 W – 83 W
range
Max. ambient temperature:
Heater: - Operation -40... +110 °C (90 °C with control unit installed on heater)
-40... +230 °F (194 °F with control unit installed on heater)
- Storage -40... +110 °C (90 °C with control unit installed on heater)
-40... +230 °F (194 °F with control unit installed on heater)
Control unit: - Operation -40... +85 °C (-40... +185 °F)
- Storage -40... +85 °C (-40... +185 °F)
Metering pump: - Operation -40... +20 °C (-40... +68 °F) -40... +40 °C (-40... +104 °F)
- Storage -40... +85 °C (-40... +185 °F)
Permitted operating pressure (heat carrier) Maximum 2.0 bar (29 PSI)
Capacity of the heat exchanger 0.15 liters (0.16 quarts)
Max. Combustion Air Inlet Temperature +40 °C (104 °F)
Minimum capacity of the circuit 6.0 liters (6.34 quarts)
Delivery rate of the circulating pump 1650 l/h (435.8 g/h)
against 0.15 bar

Page 1 of 2

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TECHNICAL DATA THERMO 90 ST

HEATER Operation THERMO 90 ST B THERMO 90 ST D

CO2 In Exhaust Gas Maximum 10... 12.0% by volume
(permitted function range)
CO2 adjustment values at approx. +20 °C Maximum 0 m (0 ft) 500 m (1640 ft) 1000 m (3280 ft)
and geographic altitude above sea level 10% 10.6% 11.3%
Heater dimensions tolerance ± L 307 mm (352* mm) [12.08 in (13.85 in*)]
(* Control unit installed on the heater) 3 mm W 131 mm (5.15 in)
(± 0.12 in) H 232 mm (9.13 in)
Weight Of Heater 4.8 kg (10.6 lb)
Table 1. Technical data (page 2 of 2)

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THERMO 90 ST TROUBLESHOOTING

5. TROUBLESHOOTING CAUTION: As a rule, fault detection is

restricted to the localization of defective
components. The following potential
5.1 GENERAL
sources of malfunctions are not taken into
account and should always be checked so
This section describes how to identify and remedy faults
that they can then be excluded as the cause
on the Thermo 90 ST air heater.
of the particular fault:
If a fault occurs, an error code will be output in the
display of the timer. If the heater has a switch, the ON • Corroded plugs
control light will flash. In addition, the heater can be
• Loose plug contacts
checked using a personal computer (see PC heater
diagnostic operating manual). • Poor crimp contacts on plugs
• Corroded cables and fuses
CAUTION: Troubleshooting work demands
• Corroded battery terminals
precise knowledge of the structure and
theory of operation of the various • Impermissibly high ambient temperature
components and must be carried out by
trained personnel only.
Conduct a function test in the vehicle after rectifying
each fault; switch the heater off and back on again first.

If in doubt, refer to sections 2 and 3 for a description of

5.2 GENERAL FAULT INDICATIONS
how the functions interact.
The following table lists the possible general fault
indications.

Fault Indication Possible Cause Remedy

Heater switches off No combustion after start and restart Control unit enters fault lock-out status.
automatically Switch heater off and then on again.

Flame extinguishes during operation Contact a Webasto service facility if

heater operation does not start again.

Heater overheats due to lack or loss of Top up coolant.

coolant After the unit has cooled down, press the
button on the temperature limiter to
reset it before switching on or fit a new
temperature limiter.

Voltage failure longer than 20 seconds Check fuses, plug connectors and charge
condition of battery

Switch off by temperature limiter After the unit has cooled down, the
temperature limiter will automatically
reset itself.

Check flame monitor and connections

No flame recognition on start

Table 2. General fault indications NOTE: In many cases, the burner may be one
possible cause. Perform a visual check in
accordance with 5.4

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TROUBLESHOOTING THERMO 90 ST

5.3 FAULT INDICATIONS ON FAULT LOCK-OUT

After five short signals, count the long flashes.
NOTE: If the system is operated with a switch,
the nature of the fault is indicated by a flashing In the Thermo 90 ST heater with a standard timer, the
code on an indicator light during the run-down fault is output on the timer display (see 3.5.2). The
time of the heater. following table can be used accordingly.

Fault indication Possible cause Remedy

No function Electrical cabling, fuses Check fuses

Check battery connections:
+ on 12 / – on 9 / + on 3, plug X8

Control unit defective Replace control unit

1 Flashing pulse Fuel system Check fuel level
(start did not occur) Check fuel filter
Bleed fuel system

Combustion air/exhaust line Check combustion air/exhaust line for foreign

bodies and clean if necessary

Burner Clean burner and change if necessary

2 Flashing pulses Fuel supply Check fuel level
(flame failure during burner Check fuel filter
operation) Bleed fuel system

Burner Clean burner and change if necessary

3 Flashing pulses Electrical power supply Check battery
(under voltage) Check electrical connections
4 Flashing pulses Flame monitor defective Replace flame monitor
(flame monitor continuously
hot)
5 Flashing pulses Cabling Check cabling for damage, discontinuity and
(flame monitor defective) short-circuit

Flame monitor defective Replace flame monitor

6 Flashing pulses Cabling Check cabling for damage, discontinuity and
(temperature sensor short-circuit
defective)
Temperature sensor defective Replace temperature sensor

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THERMO 90 ST TROUBLESHOOTING

Fault indication Possible cause Remedy

7 Flashing pulses Coolant circuit Check coolant level

(metering pump defective/ Bleed coolant circuit
(overheating guard circuit
defective)
Cabling Check cabling for damage, discontinuity and
short-circuit

Metering pump defective Replace metering pump

8 Flashing pulses Cabling Check cabling for damage, discontinuity and
(combustion air fan short-circuit
defective)
Combustion air fan defective Replace combustion air fan
9 Flashing pulses Cabling Check cabling for damage, discontinuity and
(glow pin defective) short-circuit

Ceramic glow pin defective Replace glow pin

10 Flashing pulses Heater overheats Check coolant and top up if necessary.
(overheating) After the unit has cooled down, the
temperature limiter will automatically reset
itself.
11 Flashing pulses Cabling Check cabling for damage, discontinuity and
(circulating pump defective) short-circuit

Circulating pump defective Replace circulating pump

Table 3. Fault indications on fault lock-out

(Page 2 of 2)

5.3.1 PERMANENT HEATER FAULT LOCK-OUT NOTE: The permanent fault lock-out serves as
A permanent fault lock-out is indicated by five short flash a safety feature for the customer.
pulses with no long flash pulses following.

Consecutive number of failed start

Failure Remedy
attempts

F 01 No start / no flame formation See appropriate fault indication in Table

F 03 Under voltage or over voltage 3. After eliminating the cause of a
F 04 Premature flame detection heater fault lock-out:
F 05 Flame monitor After 3 consecutive attempts, of any 1.Using switch or standard timer, turn
F 06 Temperature sensor one of the listed fault indicators, the heater on.
F 07 Fuel pump heater and control unit are locked out 2. Remove the main power connection
F 08 Fan motor with no further start attempts to heater from battery or pull fuse for a
F 09 Ceramic glow pin possible. minimum of 20 seconds.
F 10 Overheat condition 3. Using switch or standard timer
F 11 Coolant circulating pump control, turn heater off.
4. Reinstall main power connection
F 02 Flame failure After 6 consecutive attempts, heater
where previously disconnected.
and control unit are locked out.
Contact a Webasto service facility if
heater operation cannot be restored.

Table 4. Permanent heater fault lock-out

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TROUBLESHOOTING THERMO 90 ST

5.4 VISUAL CHECK FOR ASSESSING THE BURNER 5.4.1 BURNER HOUSING
• The start air hole (item 9, Fig. 10) must be clear
The burner and the evaporator in the heater display
otherwise no start will occur.
specific characteristics when they must be replaced or do
not have any fault source. Remedy
The criteria of a correct check are listed below. Carefully remove impurities from the start air hole (e.g.
using a 1.5 mm or 1/16 in. diameter wire). Remove the
glow pin first.

1 Fuel pipe
2 Round seal
9 2 3 Flame monitor
4 Insulation
5 Glow pin
6 Housing
7 Screw
8 Bar
9 Start air hole

8 3

7 4

6 5

Figure 10: Visual check, burner back wall

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THERMO 90 ST TROUBLESHOOTING

5.4.2 BACK WALL WITH METAL EVAPORATOR 5.4.3 COMBUSTION CHAMBER

The pilot flame outlet opening (Fig. 11) must be clear • The combustion chamber (Fig. 12) should not be
otherwise no start will occur. damaged (e.g. dented). A dented combustion
chamber can lead to poor combustion or carbon
Remedy build-up in the heater.
Replace burner
Remedy
Replace burner
• Cracks, flaking as well as black or other discoloration
of the evaporator do not lead to burner failure and
are not significant. • The air holes (Fig. 12) in the combustion chamber
• Coke deposits on the evaporator surface (except for must not be blocked up by carbon deposits. If the air
the pilot flame outlet opening) are normal; as a rule, holes are blocked up by carbon deposits, this may
the burner cleans itself due to the load changes from result in failure of combustion to start or to run
full load to part load and part load to full load. effectively.

Remedy

Pilot flame outlet opening Carefully scratch clear the air holes

5.4.4 COMPLETE BURNER

• The cables of the glow pin and flame monitor must
be routed as shown in Fig. 10.
• The screw connection of the housing and
combustion chamber (Fig. 12) must be tight.
• The housing and the combustion chamber (Fig. 12)
must be firmly connected together and there must
not be any play (check by moving the fuel pipe
slightly).
• The round sealing ring (item 2, Fig. 10) must evenly
surround the fuel pipe and must not leak.
• The distance (gap) between the edge of the housing
Metal evaporator, gasoline and the top edge of the combustion chamber
(Fig. 12) does not have to be even all the way
around.
• The insulation (item 4, Fig. 10) must not be missing.
Pilot flame outlet opening

Combustion chamber Air swirl plate

Air holes
Metal evaporator, diesel
Gap between housing
and combustion chamber
Figure 11: Visual check, pilot flame outlet opening Figure 12: Visual check, complete burner

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TROUBLESHOOTING THERMO 90 ST

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THERMO 90 ST TROUBLESHOOTING

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TROUBLESHOOTING THERMO 90 ST

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THERMO 90 ST FUNCTIONAL TESTS

6. FUNCTIONAL TESTS 6.3.2 RESISTANCE TEST OF THE CERAMIC GLOW PIN

If you conduct this electrical test with a digital
6.1 GENERAL multimeter, the glow pin should have the following
values:
This section describes the tests conducted on the heater
Glow pin: 12 V (red) 24 V (green)
when it is installed and not installed to verify that it is in
working order. Resistance at 25 °C : 0.3 ... 0.6  1.3 ... 1.44 
Resistance at 77 °F : 0.3 ... 0.6  1.3 ... 1.44 
WARNING: The heater must not be Test current: < 5 mA < 5 mA
operated in enclosed areas such as garages
and workshops without an emissions
extraction system.
6.3.3 RESISTANCE TEST ON THE FLAME MONITOR
If you conduct this test with a digital multimeter, the
flame monitor must have the following values:
6.2 SETTINGS
Cold Testing:
6.2.1 SETTING THE CO2 CONTENT Resistance at 25 °C (77 °F): 3.0 ± 0.4 
It is permitted for the factory-set combustion air quantity Test current: < 5mA
to be modified. This is achieved by turning the air
Hot Testing:
regulating screw.
Resistance at 800 ± 20 °C: 8 ± 1.0 
Setting procedure Resistance at 1472 ± 36 °F: 8 ± 1.0 
Turning clockwise: CO2 value is reduced (let the heater (ceramic rod at red heat over length of approx. 20 mm)
run for about 5 minutes before measuring).
Test current: < 5 mA
Rough setting: Screw the adjusting screw fully in
clockwise and then one turn back

CAUTION: .The CO2 measuring 6.3.4 TESTING THE COMBUSTION AIR FAN
instruments must be calibrated. The motor speed test must be performed with the heater
assembled and in the operating voltage range. Listen out
for grinding noises.

6.3 TESTING INDIVIDUAL COMPONENTS NOTE: The cover must be removed from the
fan in order to check the motor speed. Install a
new seal before re-installing.
6.3.1 RESISTANCE TEST OF THE TEMPERATURE
SENSOR
CAUTION: Make sure the detent lugs do
If you conduct this electrical test with a digital not break off.
multimeter, the temperature sensor should have the Fit a new cover and a new seal if the detent
following values at room temperature: lugs have broken off.
Resistance at 25 °C: 990 ... 1010 
Test current: < 1 mA
Speed in control range min. 1800 rpm (±9%)
Speed in control range max. 5600 rpm (±9%)
Install a new combustion air fan if the speeds are outside
tolerance (see 9.2.4).

www.webasto.us 19 Webasto Thermo & Comfort N.A., Inc.

FUNCTIONAL TESTS THERMO 90 ST

This page for your notes.

Webasto Thermo & Comfort N.A., Inc. 20 www.techwebasto.com

THERMO 90 ST CIRCUIT DIAGRAMS

7. CIRCUIT DIAGRAMS Item Designation Comment

7.1 GENERAL H3 Symbol light Light (in item P2)

H6 Red LED Immediate heat
The circuit diagrams (Figs. 13 and 14) show the possible button light, ready
circuits for the Thermo 90 ST heater with indicator, switch-on
– Standard switch control (in item P2)
– Standard timer K1 Relay Vehicle fan interface
harness option
7.2 THERMO 90 ST CIRCUIT DIAGRAM LEGEND M1 Motor Combustion air fan
M2 Motor Circulating pump
 Digital timer P2:
Connection X14 to Red jumper of switch harness results P2 Digital timer 1531 For programmed
in continuous operation with immediate heating operation
(recommended for trucks requiring sleeper heating) S1 Toggle switch ON/OFF
Connection X14 to vehicle ignition connection results in X1 Plug connector, 4-pin To item A2
variable heating duration that can be programmed
(10 min. to 120 min.); default setting 120 min. when X2 Plug connector, 2-pin To item A2
ignition key is switched off. (Recommended for School X3 Plug connector, 2-pin To item A2
bus, Coach and Transit vehicles.)
X4 Plug connector, 2-pin To item A2
 Optional connection to vehicle instrumentation
panel lighting circuit. X5 Plug connector, 2-pin To item A2
X6 Plug connector, 2-pin To item A2
The following Table applies to Figures 13 and 14. X7 Plug connector, 2-pin To item A2

Item Designation Comment X8 12-pin plug To item A2

connection
A1 Heater
X9 12-pin plug To item P2
A2 Control module connection
B1 Flame sensor X10 Plug connector, 2-pin W-Bus Diagnostics
B2 Temperature sensor X11 Plug connector, 2-pin To Y1
B3 Temperature limiter/ X12 9-pin plug connection Power/Control
Overheating guard Harness
B4 Room thermostat X13 Plug connector, 8-pin To X9 of item P2
BT Battery Vehicle battery X14 Plug connector, 1-pin To pin-10 of item X9
DS Illuminated toggle Operating indicator (in (see )
item S1) X15 Plug connector, 3-pin To optional blower
E Glow plug interface systems
(Sleeper Pak™)
F1 Fuse 10 A ATM mini flat fuse
X16 5-pin relay socket Vehicle fan interface
F2 Fuse 5 A ATM mini flat fuse harness option
F3 Fuse 20 A ATM mini flat fuse Y1 Metering pump Fuel pump for heater
H1 “Heating” symbol in Operating indicator
the display (in item P2)

www.webasto.us 21 Webasto Thermo & Comfort N.A., Inc.

 B4
00
11

Figure 13:
4 2 3 1 5

Optional Blower Interface Harness P/N 905613B

White

Black
K1 Green
X15 X8
86 85 Green Black A Violet 1 A2
Green B Brown 8
CIRCUIT DIAGRAMS

X10 2
12V + White 30 87 White White C White 1
5
Yellow/Red 6
87a 2
10
X16

Black
GND 11

Webasto Thermo & Comfort N.A., Inc.

Black

X12

Violet
Black B Black

D Violet Black
White 3
DS Green C White White 4
Black Red F1 F2 F3
Red A Red

White
Brown
A B C D E F
S1

Red
White
Red
Red
Red

22
Red
F5 Red E Red
Red F Red
BT Red/Black
Brown G Brown 12

Brown Brown H Brown Brown 9

White J Brown Gray
7
1 2 2 1 1 2 4 1 2 1 2 1 2 1 2

X2 X4 X1 X5 X6 X7 X3

E B2 B3
Yellow
Red
Brown
Black
Blue
White/Blue
Violet
Violet/Blue
Gray
Orange
Orange
Green
Blue
Brown

X11
1 2
M1
M2
Yellow
Brown
Brown
Black
Blue
Brown
Violet
Violet
Gray
Gray
Green
Green

B1 M M
E M1 M2
B3 B1 B2 Y1

A1

X1 X2 X3 X4/X5/X6/X7 X8 X10 X11 X12 X15

1 2

Thermo 90 ST with On/Off switch - connection diagram (Includes optional blower interface harness)
2 B A
2 1 2
2
3 1
1 1 11 C
4 9 2
7 1 2
5 1
3
1
THERMO 90 ST

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 Figure 14:
1
2
3
E B2 B3 X1 X2 X3 X4/X5/X6/X7 X8 X9 X10 X11 X12 4 X13 X15

www.webasto.us
1 2

2 B A
M1 2 1 2 3
2
THERMO 90 ST

3 1 6
1 1 11 9 C
4 9 12 2
M2 7 1 2
5 1
3 5
1 6
B1 7
8

X15 X8
A Violet 1 A2
B Brown 8
X10 2
C White 1
5
Yellow/Red
6
2
10
11
X14
Violet 
Black
X12

Violet
X13 Black B Black
Black 6
X9 D Violet Black
3
Gray 3
Green C White White 4
1 10
11 Yellow 4 Red

23
  F1 F2 F3
Red 1 Red A Red

White
P2
Brown
A B C D E F
2
2

Red
White
Red
Red
Red
White
7 Red
F5 Red E Red
H3 H1
8 Red F Red
Brown 5
H6 Brown BT Red/Black
8 Brown G Brown 12
12 4 Brown H Brown Brown
7 Brown 9
White J Brown Gray
7
1 2 2 1 1 2 4 1 2 1 2 1 2 1 2

Thermo 90 ST with 7-day digital timer model 1531 - connection diagram

X2 X4 X1 X5 X6 X7 X3
Yellow
Red
Brown
Black
Blue
White/Blue
Violet
Violet/Blue
Gray
Orange
Orange
Green
Blue
Brown

X11
1 2
Yellow
Brown
Brown
Black
Blue
Brown
Violet
Violet
Gray
Gray
Green
Green

M M
E M1 M2
B3 B1 B2 Y1

A1
CIRCUIT DIAGRAMS

Webasto Thermo & Comfort N.A., Inc.

CIRCUIT DIAGRAMS THERMO 90 ST

This page for your notes.

Webasto Thermo & Comfort N.A., Inc. 24 www.techwebasto.com

THERMO 90 ST SERVICING WORK

8. SERVICING WORK 8.4 HEATER TRIAL

8.1 GENERAL WARNING: The heater must not be

operated in enclosed areas such as garages
This section describes the servicing work that can be and workshops without an emissions
carried out on the heater when it is installed. extraction system, even if the heater is
equipped with a timer.
8.2 WORK ON THE HEATER
8.5 SERVICE WORK
Disconnect the main power cable from the vehicle’s
battery before carrying out any work on the heater. The NOTE: The heater should be operated for
main battery power must not be disconnected whilst the approximately 20 minutes every 4 weeks to
heater is operating or slowing down as a result of the risk prevent mechanical parts seizing.
of the heater overheating and the overheating guard
thus being tripped. The following service work is to be carried out after or
before each heating period to maintain the functional
If you wish to carry out extensive repair work on the reliability of the heater:
heater, it may be a good idea to remove it completely.
After working on the heating circuit, top up with a • Clean the exterior of the heater (avoid the ingress of
coolant mixture of water and antifreeze according to the water).
manufacturer’s instructions and carefully bleed the • Check the electrical connections for contact
heating circuit. corrosion and to ensure that they are secure.
Refer to the relevant installation instructions and the • Check the exhaust and combustion air lines for signs
installation proposal for the heater for the specific vehicle of damage and to ensure that they are clear.
for repairs that necessitate the installation position being • Check the fuel line and filter for leaks.
changed.
• Check the coolant circuit and circulating pump for
leaks.
8.3 WORK ON THE VEHICLE
• Inspect hoses for cracks.
CAUTION: A temperature of 90 °C (194 °F) • Replace the fuel filter if there is one.
must not be exceeded in the vicinity of the
heater in any circumstances (for example
when completing painting work on the
vehicle). See Section 4.

www.webasto.us 25 Webasto Thermo & Comfort N.A., Inc.

 Figure 15:
SERVICING WORK

Webasto Thermo & Comfort N.A., Inc.

13

Installation example of a heater in a truck

12 14

26
7 6
1 15

2 9 10 11
3 8
4 5

1 Thermo 90 ST water heater 6 Fuse block 11 Fuel standpipe

2 Control unit 7 Vehicle batteries 12 Heat exchanger - vehicle heating
3 Circulating pump 8 Fuel line 13 Digital timer
4 Combustion air intake 9 Fuel metering pump 14 Coolant hose to heater inlet
5 Exhaust outlet with muffler 10 Fuel filter (optional) 15 Return coolant hose from heater
THERMO 90 ST

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THERMO 90 ST SERVICING WORK

8.6 VISUAL INSPECTIONS AND INSTALLATION

INSTRUCTIONS Permissible fuel inflow At max. pressure (bar) in
height H (m) fuel line
8.6.1 CONNECTION TO THE VEHICLE COOLING 0.00 m (0.00 in.) 0.20 bar (2.9 PSI)
SYSTEM
1.00 m (39.4 in.) 0.11 bar (1.6 PSI)
In thermostat circuits, only use thermostats which start to 2.00 m (78.7 in.) 0.03 bar (0.44 PSI)
open at < 65 °C (< 149 °F).
Maximum fuel intake At max. negative pressure
The heater should be installed in as low a position as height S (m) (bar) in fuel tank
possible to allow the heater and circulating pump to be 0.00 m (0.00 in.) -0.10 bar (-1.45 PSI)
bled automatically.
0.50 m (19.7 in.) -0.06 bar (-0.87 PSI)
This is particularly important as the circulating pump is
not self-priming. 1.00 m (39.4 in.) -0.02 bar (-0.29 PSI)
The heater is connected to the vehicle cooling system as
shown in Fig. 15. The system must contain at least
6 liters (6.34 quarts) of coolant. NOTE: A sign must be affixed to the fuel filler
neck warning that the heater must be switched
The coolant hoses supplied by Webasto must always be
off before refuelling.
used. If you do not use these hoses, the hoses that you
do use must comply with DIN 73411. The hoses must be
installed without kinks and (to ensure proper bleeding)
rising if possible.
Hose connections must be supported by hose clips to
prevent them slipping.

NOTE: The hose clips must be tightened with max. 3m (9.8 ft.)
a torque of 4 Nm.
I2

The cooling system must be bled carefully before using iØ2mm

the heater for the first time or after replacing the
coolant. The heater and lines should be installed in such iØ2mm H
a way as to ensure static bleeding.
Proper bleeding can be identified by the circulating pump
operating almost silently. Poor bleeding may cause the
resetting temperature limiter to trip while the heater is in iØ2mm I1
operation.
I2
iØ2mm

8.6.2 CONNECTION TO THE VEHICLE FUEL SYSTEM S

The fuel is taken from the vehicle fuel tank or from a I 1 + I 2 ≤ 10 m (32.8 ft.) I1
separate fuel tank. I 1 ≤ 1.2 m (3.9 ft.)
The values for the maximum pressure at the fuel I 2 ≤ 8.8 m (28.8 ft.)
extraction point are shown in the table below.
Figure 16: Fuel supply

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SERVICING WORK THERMO 90 ST

8.6.2.1 FUEL EXTRACTION

Vehicles with Diesel Engines Sealing ring
The fuel must be taken from the vehicle fuel tank or from
a separate tank (Figs. 17, 18 and 19).

Hole pattern

Metal tank fitting

or sender plate

25 mm (1 in.)
> 25 mm (> 1 in.)

Max. depth
Figure 19: Fuel standpipe for a plastic or metal tank
(extraction through metal tank fitting)

Figure 17: Webasto fuel standpipe NOTE: Deburr the cut on the fuel extractor
after sawing it off and remove any metal chips
NOTE: Only use this style of standpipe with
metal fuel tanks.
Vehicles with Gasoline Engines

Plastic tank The heater must be integrated into the return line of fuel
systems in carburetor and injection engines with a return
line.
In carburetor engines without a return line the heater
must be integrated into the fuel system in the supply line
between the fuel tank and the vehicle pump.

IMPORTANT!

• A fuel feed line can normally be identified by the fact

that a fuel filter is installed in it.
• If there is an evaporation tank in the vehicle’s fuel
system, the fuel must be extracted upstream of the
Sealing ring evaporation tank.
Fuel may only be taken from the supply or return line
using the special Webasto fuel extractor tee (Fig. 20).
The fuel extractor must be fitted in such a way that any
air or gas bubbles are automatically discharged towards
the tank (Fig. 20). Air or gas bubbles may be produced in
Figure 18: Fuel extractor from a plastic or metal tank
the vehicle’s fuel line if there are leaks in the carburetor
(extraction through tank drain screw)

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THERMO 90 ST SERVICING WORK

or vehicle fuel pump or if the ambient temperature is Unsupported fuel lines must be secured to prevent them
higher than the evaporation temperature of the fuel. sagging. They must be installed in such a way that they
cannot be damaged by flying road debris and high
The fuel extractor should not be located near the engine,
temperatures (exhaust line).
as gas bubbles may form in the lines on account of heat
radiated from the engine. This may cause problems The fuel lines must be secure at the connections using
during combustion. hose clips to prevent their slipping.
When installing the heater in a vehicle with fuel injection Connecting Two Fuel Lines with a Hose
system, it is important to establish whether the fuel
pump is located inside or outside the tank. If the fuel The correct procedure for connecting fuel lines with
pump is located inside the tank, fuel can only be hosing is shown in Fig. 21.
extracted from the return line. In this case it must be
ensured that the return line continues almost to the
Correct
bottom of the tank and is not sealed by a non-return
valve. If this is not the case the return line may be
extended. If the fuel pump is installed outside the tank, Clamp
the fuel connection may be made between the tank and
the fuel pump.

Wrong
a= 6 Ø
8Ø Bubble Bubble
Ø 5 10 Ø

0-60° 12 Ø 0-60° 0-60°

0-60°
From Tank
Figure 21: Fuel line connections
To Engine

8.6.3 FUEL METERING PUMP

0-60° 0-60°
To Fuel Metering Pump
The metering pump is a combined delivery, metering and
shut-off system and is subject to certain installation
Figure 20: Webasto fuel extractor tee installation criteria (Fig. 16 and 22).

8.6.2.2 FUEL LINES 12 V and 24 V – Diesel DP 30 (with damper)

Only steel, copper and plastic lines of plasticized, light
and temperature-stabilized PA11 or PA12 (for example
Mecanyl RWTL) according to DIN 73378 may be used for
the fuel lines.

NOTE: Cut Mecanyl lines without burr and do

0-90° 0-90°
not crush them. Do not cut them with side-
0°
cutting pliers.
Install in horizontal position only!
Since the lines cannot normally be routed with a constant
rising gradient, the internal diameter must not be Figure 22: Metering pump, installation position and
allowed to exceed a certain size. Air or gas bubbles will attachment
accumulate in lines with an internal diameter of more
than 4 mm (5/32 in) and these will cause malfunctions if 8.6.3.1 INSTALLATION POSITION
the lines sag or are routed downwards. The diameters
specified in Fig. 16 will ensure that bubbles do not form. Before installing the fuel metering pump, ensure that the
maximum pressure occurring at the fuel pickup point is
The lines should not be routed downwards from the less than 0.2 bar (2.9 PSI).
metering pump to the heater.

www.webasto.us 29 Webasto Thermo & Comfort N.A., Inc.

SERVICING WORK THERMO 90 ST

It is advisable to install the metering pump in a cool The combustion air inlet must not be routed above the
place. The maximum ambient temperature must not exhaust outlet.
exceed +20 °C (+68 °F) for gasoline and
+40 °C (+104 °F) for diesel at any time during operation. NOTE: If the combustion air intake line cannot
be installed so that it slopes downwards, a
The metering pump and fuel lines must not be installed
water drain hole with a diameter of 4 mm
within range of the radiated heat from hot vehicle parts.
(5/32 in) is to be made at its lowest point.
A heat shield must be used if necessary.
The pump should ideally be installed near the tank. If the heater is installed in a general installation space
near the vehicle’s fuel tank, the combustion air must be
8.6.3.2 INSTALLATION AND ATTACHMENT taken in from the outside and the exhaust fumes
discharged into the atmosphere. The openings must be
The metering pump must be secured with a vibration-
splash-proof.
damping mounting. Its installation position is limited as
shown in Fig. 22 in order to ensure effective automatic A ventilation opening measuring at least 6 cm2 (1 in2) is
bleeding. required if the heater is installed in an enclosed box. The
As a result of the risk of corrosion, only genuine Webasto size of the ventilation opening must be increased
parts may be used for the plug connections between the accordingly if the temperature in the box exceeds the
metering pump and the metering pump wiring harness. permitted ambient temperature of the heater (see
Technical data).
8.6.4 FUEL FILTER
8.6.6 EXHAUST LINE
Only a Webasto filter, P/N 50487171A, is allowed to be
used if the fuel is expected to be contaminated. Install The exhaust line (internal diameter 38 mm) can be
vertically if possible, however at most horizontally (check installed with a length of 0.5 m to 5 m and several bends
flow direction). (360° altogether, minimum bending radius 85 mm). The
exhaust muffler is essential and must be installed near
the heater.
An attachment is required no further than 150 mm (6 in)
from the end of the exhaust pipe to ensure that the
0° - 90° angle of 90° ±10° is achieved.

Ø5
Discharge direction
Figure 23: Fuel filter more or less vertical
90° ± 10°
8.6.5 COMBUSTION AIR SUPPLY
Under no circumstances may the combustion air be
taken from areas occupied by people. The combustion 10°
air intake opening must not point in the direction of 10°
travel.
It must be located so that it cannot become clogged with
dirt or snow and cannot suck in splashing water.
The combustion air intake line (internal diameter at least
30 mm) may be 0.5 m to 5 m long with several bends
totalling 360°. Minimum bending radius is 45 mm. Figure 24: Exhaust pipe opening, installation position

Webasto Thermo & Comfort N.A., Inc. 30 www.techwebasto.com

THERMO 90 ST SERVICING WORK

The opening of the exhaust pipe must not point towards 8.7.1.2 INSTALLATION
the front of the vehicle (see Figure 24).
1. Position the heater in its installation position and
The exhaust pipe opening must be located so that it screw in 3 screws with washers to attach it.
cannot become clogged with snow and mud.
2. Connect the coolant hoses and secure with hose
Rigid pipes of unalloyed or alloyed steel with a minimum clips. Tighten the hose clips to 5 Nm (44 lb-in).
wall thickness of 1.0 mm or flexible piping of alloyed
3. Secure the connection for the combustion air inlet
steel only must be used as the exhaust line. The exhaust
on the heater.
pipe is secured to the heater using a clamping collar, for
example. See your local jurisdiction for statutory 4. Secure the connections for the combustion air inlet
regulations for other requirements that may be in force. and exhaust outlet on the heater.
5. Connect the wiring harness plug to the heater.
8.7 REMOVAL AND INSTALLATION 6. Put on the top cover cap and lock it in place.
7. Connect the battery.
CAUTION: When the heater is installed,
only the following dismantling or removal 8. Bleed the fuel supply system.
procedures are permitted providing the 9. Bleed the coolant circuit.
upper cover cap is accessible and can be
removed, and there is sufficient room for 8.7.2 CHANGING THE CIRCULATING PUMP
removal:
NOTE: The process for changing the
– Changing the circulating pump circulating pump is the same irrespective of
– Changing the temperature limiter whether the heater is installed or removed.
Change as described in 9.2.1.
– Changing the temperature sensor
– Changing the combustion air fan 8.7.3 CHANGING THE TEMPERATURE LIMITER
– Changing the control unit
NOTE: The process for changing the
8.7.1 HEATER, REMOVAL AND INSTALLATION temperature limiter is the same irrespective of
whether the heater is installed or removed.
8.7.1.1 REMOVAL Change as described in 9.2.2.

1. Disconnect the battery. 8.7.4 CHANGING THE TEMPERATURE SENSOR

2. Remove the upper cover cap.
3. Disconnect the wiring harness plug from the heater. NOTE: The process for changing the
temperature sensor is the same irrespective of
4. Disconnect the connection for the combustion air
whether the heater is installed or removed.
inlet on the heater.
Change as described in 9.2.3.
5. Unfasten the hose clips and pull the coolant hoses
off the heater. 8.7.5 CHANGING THE COMBUSTION AIR FAN
6. Disconnect the connections for the combustion air
inlet and exhaust outlet on the heater. NOTE: The process for changing the
7. Remove three screws and washers from the heater combustion air fan is the same irrespective of
holder. whether the heater is installed or removed.
Change as described in 9.2.4.
8. Remove the heater.

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SERVICING WORK THERMO 90 ST

8.8 START-UP

After you have installed the heater, bleed the coolant circuit and the fuel supply system carefully. Comply with the
instructions given by the vehicle manufacturer when doing this. During the trial run, check all coolant and fuel
connections for leaks and to ensure that they are secure. If the heater suffers a fault during operation, the fault must
be located and remedied (see section 5).
Before starting the heater for the first time, complete the following checklist.

HEATER MOUNTING Complete

(Yes/No/Comments)
1 Is the heater installation safely secure / rigid?
(Ensure that all bracket bolts are tight)
2 Is there a safe clearance from heat generating
Components? (I.e. exhaust, etc...)
3 Is there sufficient clearance between heater and any
vehicle moving components under all operating
conditions? (steering cranked to extreme positions,
torqued engine, suspension, etc...)
4 Is the heater mounted in an acceptable position
according to the limitations noted in the
installation manual?
5 Is the heater installed in a protected location from
road debris and splash-water or items stored in the same area?
6 Is there a sufficient amount clearance
between the heater and the ground? (Coolant heaters only)

COOLANT SYSTEM Complete (Yes/No/

Comments)
1 Is there a safe clearance (min 4 in.) from heat generating components?
(exhaust, etc...)
2 Is there a safe clearance from sharp edges / objects?
Ensure a heat protective has been installed (if applicable)
3 Are there any kinks, sharp bends or the possibility for pinched hoses or
harnesses, cuts and rub through?
4 Have all the hose clamps been properly positioned and tightened?
5 Has the coolant system been topped off and bleed per the vehicle
manufacture’s specifications for proper mixture and type?
6 Has a pressure test been performed on the coolant system under all
operating conditions?
7 Have the coolant hoses been installed so that they are below the coolant
filler cap?
8 Has the coolant flow direction been verified?

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THERMO 90 ST SERVICING WORK

ELECTRICAL Complete
(Yes/No/Comments)
1 Has all wiring been safely secured away from moving components
and / or heat sources?
2 Check for proper power and ground connections.
3 Has blower motor functionality been tested (if applicable)?
4 Check for proper fuse tap connection.
5 Verify the correct fuses are in the specified locations per the installation
manual.
6 Ensure heater and vehicle fuse boxes are closed and secure. Was the
Webasto fuse block installed in a location protected from water and / or
moisture?
7 Ensure blower motor resistor (1.0?) is securely mounted and has sufficient
clearance from any plastic component and battery.
8 Ensure battery is mounted securely and connections are properly tightened.
9 Ensure battery is at ? 12.2Vdc.

FUEL SYSTEM Complete (Yes/No/

Comments)
1 Is the standpipe properly mounted in the fuel tank?
(sealed, structural integrity maintained).
2 Validate the standpipe does not interfere with function of sending unit by
checking fuel gauge for proper operation before completing installation of
tank.
3 Verify that all fuel lines are properly secured and are a safe distance (min. 4
in.) from exhaust systems and / or moving components.
4 Check all fuel lines for leaks or kinks.
5 Check fuel line clamps for proper positioning and tightness. Ensure fuel
system is free of leaks.
6 Ensure fuel pump is securely mounted in a cool location
NOTE: Vehicle fuel tank area is generally a location with minimal sound
transfer path to vehicle interior.

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SERVICING WORK THERMO 90 ST

EXHAUST SYSTEMS Complete

(Yes/No/Comments)
1 Is the muffler and clamps securely tightened?
2 Has muffler and exhaust tube been routed a safe distance (min. 2 in.) from
flammable material?
3 Ensure drain-holes are drilled in low bend areas of exhaust tube.
4
Ensure exhaust is venting a safe distance from any vehicle interior openings.

5 Ensure exhaust is venting in the direction that will not cause back pressure
while driving.

COMBUSTION AIR INTAKE Complete

(Yes/No/Comments)
1 Is the combustion air intake drawing fresh air from a non-turbulent location?
(i.e. not in direction of travel)
2 Ensure air intake system is securely fastened.

HEATER FUNCTION Complete (Yes/No/

Comments)
1 Ensure heater starts and runs for a minimum of 20 minutes.
2 Ensure vehicle blower turns “ON”.
3
Ensure warm air is blown out of interior vents after blower is activated.

4
Ensure timer (control device) is functioning.

5 Check and Modify CO2 setting as needed based on altitude (will the heater
“live” or spend a lot of time above XXXXXX Feet)
(See service manual for instructions to make adjustment)

COSMETICS Complete (Yes/No/

Comments)
1 Has the vehicle interior, engine compartment, trunk & glove compartment
been inspected for cleanliness after installation.
2 Has user manual placed in glove box?
3 Is the vehicle clock time correct after disconnecting the battery?

If you have any questions, contact our technical support team at (800) 860-7866 or via email at:
[email protected].

Webasto Thermo & Comfort N.A., Inc. 34 www.techwebasto.com

SERVICING WORK THERMO 90 ST

This page for your notes.

Webasto Thermo & Comfort N.A., Inc. 35 www.techwebasto.com

SERVICING WORK THERMO 90 ST

Webasto Thermo & Comfort N.A., Inc. 36 www.techwebasto.com

THERMO 90 ST REPAIR

9. REPAIR • Inspect the plugs and cables for corrosion, loose

contacts, crimping faults, etc. and repair them if
necessary.
9.1 GENERAL
• Check plug contacts for signs of corrosion and to
This section describes the repair work that may be carried ensure they are secure. Repair them if necessary.
out on the Thermo 90 ST heater after it has been
removed from the vehicle. Any further dismantling will 9.2 DISMANTLING AND ASSEMBLING
invalidate the warranty. Only use the spare parts from
the appropriate spare parts kits for assembling the 9.2.1 REPLACING THE CIRCULATING PUMP
heater.
9.2.1.1 REMOVAL
9.1.1 WORK ON STRIPPED-DOWN COMPONENTS
1. Remove the heater (see 8.7.1.1).
CAUTION: All sealing elements between 2. Remove the screws (4, Fig. 25).
the stripped-down components must
3. Remove the clip (3) and circulating pump (2).
always be discarded and replaced with
new. 4. Unplug electrical cable from control unit.
5. Complete the work on stripped-down components
9.1.1.1 CLEANING (see 9.1.1).
• Clean all stripped-down components.
9.2.1.2 INSTALLATION
• Remove all seal residue on the components carefully
using a suitable tool. 1. Apply acid-free grease (Vaseline) to the sealing ring
(1, Fig. 25).
9.1.1.2 VISUAL INSPECTION 2. Place the circulating pump (2, Fig. 25) in the
assembly position and attach with the clip (3) and
• Check all components for damage (cracks,
screws (4).
deformation, wear, etc.) and fit new ones if
necessary. 3. Tighten the screws (4) to 3 Nm (26.5 lb-in) ±10%.
4. Plug electrical cable into control unit.
5. Install the heater (see 8.7.1.2).

www.webasto.us 37 Webasto Thermo & Comfort N.A., Inc.

REPAIR THERMO 90 ST

1 Sealing ring
2 Circulating pump
3 Clip 3
4 Screw (2)

Figure 25: Replacing the circulating pump

Webasto Thermo & Comfort N.A., Inc. 38 www.techwebasto.com

THERMO 90 ST REPAIR

9.2.2 REPLACING THE TEMPERATURE LIMITER 9.2.3 REPLACING THE TEMPERATURE SENSOR

9.2.2.1 REMOVAL 9.2.3.1 REMOVAL

1. Remove the heater (see 8.7.1.1).
NOTE: The temperature limiter only has to be
removed if it is being replaced with a new one.
WARNING: Leaking hot coolant can cause
The function must be checked in the installed
burns.
condition.

1. Remove the heater (see 8.7.1.1).

2. Unscrew and remove the temperature sensor
2. Remove the clip (2, Fig. 26) and pull off the
(6, Fig. 26) and remove it together with the round
protective cap (1).
sealing ring (5).
3. Use a screwdriver to lever off the retaining spring
and remove the temperature limiter (3). 3. Unplug electrical cable from control unit.

4. Unplug electrical cable from control unit. 4. Complete the work on stripped-down components
(see 9.1.1).
5. Complete the work on stripped-down components
(see 9.1.1). 9.2.3.2 INSTALLATION
NOTE: It is essential to fit a new temperature 1. Apply acid-free grease (Vaseline) to the round
limiter to replace a removed one! sealing ring (5, Fig. 26).
2. Fit the temperature sensor (6) with the round
sealing ring (5) and screw it into the heat exchanger
(4). Tighten to 1.5 Nm (13.3 lb-in) ±10%.
9.2.2.2 INSTALLATION 3. Plug electrical cable into control unit.
CAUTION: Incorrect installation will cause 4. Install the heater (see 8.7.1.2).
the heat exchanger to melt.

1. Insert the new temperature limiter (3, Fig. 26) into

the heat exchanger (4) and press in the retaining
spring.

NOTE: You must be able to hear and feel the

spring clip into the groove. Only then is the
temperature limiter in the correct installation
position.

If you do not hear and feel the spring clip in:

• Clean the contact surface of the temperature limiter
on the heat exchanger
• Clean the groove in the heat exchanger
• Ensure that the detent lugs are present on both sides
of the spring. Fit a new temperature limiter if
necessary.
2. Put on the protective cap (1) and secure it with the
clip (2).
3. Tighten the clip to 1 Nm (8.8 lb-in) ±10%.
4. Plug electrical cable into control unit.
5. Install the heater (see 8.7.1.2).

www.webasto.us 39 Webasto Thermo & Comfort N.A., Inc.

REPAIR THERMO 90 ST

1 Protective cap
2 Clamp
3 Temperature limiter
4 Heat exchanger 1
5 Round sealing ring
6 Temperature sensor

6 4

Figure 26: Replacing the temperature limiter and

temperature sensor

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THERMO 90 ST REPAIR

9.2.4 REPLACING THE COMBUSTION AIR FAN 9.2.4.2 INSTALLATION

9.2.4.1 REMOVAL NOTE: Insert the shaped seal (3, Fig. 27)
correctly and grease it (e.g. with Vaseline). Take
1. Remove the heater (see 8.7.1.1). care not to squash it.
2. Remove the screws (2, Fig. 27).
3. Pull the combustion air fan (1) off the burner head 1. Fit the new shaped sealing ring (3) onto the
(4) and remove together with the shaped sealing combustion air fan (1). Bring the fan into the
ring (3). assembly position and secure it with screws (2).
2. Tighten the screws (2) to 3 Nm (26.5 lb-in) ±10%.
NOTE: Remove the control unit if necessary
from the Thermo 90 ST heater with flange- NOTE: Install the control unit if necessary on
mounted control unit. the Thermo 90 ST heater with flange-mounted
control unit.
4. Unplug electrical cable from control unit.
5. Complete the work on stripped-down components 3. Plug electrical cable into control unit.
(see 9.1.1). 4. Install the heater (see 8.7.1.2).

1 Combustion air fan

2 Screw (2)
3 Shaped sealing ring
4 Burner head
5 Control unit
2 3

1
5

Figure 27: Replacing the combustion air fan

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REPAIR THERMO 90 ST

9.2.5 REPLACING THE BURNER, FLAME MONITOR AND CAUTION: During the following
GLOW PIN procedure, make sure that the cables of the
flame monitor (7) and the glow pin (6) are
9.2.5.1 REMOVAL routed as shown in the figure.

1. Remove the heater (see 8.7.1.1).

2. Remove the combustion air fan (see 9.2.4.1).
3. Remove the screw (5, Fig. 28) and washer (4).
4. Remove the nuts (10) and pull off the bar (8).
5. Pull the grommets (11 and 12) out of the slots in the
housing of the combustion pipe (3).
6. Pull the grommet (13) and burner (1) out of the
burner head and remove with the air swirl plate (2).
7. Pull the flame monitor (7) and glow pin (6) from the
burner (1) and remove.
8. Perform a visual check for assessing the burner
(see 5.4).
9. Complete the work on stripped-down components
(see 9.1.1).

9.2.5.2 INSTALLATION Flame monitor

Glow pin
1. Place the air swirl plate (2, Fig. 28) onto the burner
(1).
2. Carefully insert the flame monitor (7) and glow pin
(6) into the burner up to the stop and push the
grommets (11 and 12) into the slots in the housing 4. Push the insulation (9) onto the bar (8) and bring
of the burner pipe (3). the bar into the assembly position.
3. Insert the burner (1) and grommet (13) into the
burner head (3). NOTE: Route the cable of the flame monitor
and the glow pin as shown in the figure!

5. Secure the bar (8) using the nuts (10). Tighten the
nuts to 3 Nm (26.5 lb-in) ±10%.
6. Secure the fuel line using the screw (5) and
washer (4). Tighten the screw to 3 Nm (26.5 lb-in)
±10%.
7. Install the combustion air fan (see 9.2.4.2).
8. Plug in any electrical cables removed from the
control unit.
9. Install the heater (see 8.7.1.2).

Webasto Thermo & Comfort N.A., Inc. 42 www.techwebasto.com

THERMO 90 ST REPAIR

1 Burner
2 Air swirl plate
3 Burner head
4 Washer
5 Screw
6 Glow pin
7 Flame monitor
13 1 8 Bar
9 Insulation
10 Nut (2)
11 Grommet
12 12 Grommet
13 Grommet

11

8
9
10

2
4
5

Figure 28: Replacing the burner, flame monitor and

glow pin

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REPAIR THERMO 90 ST

9.2.6 REPLACING THE BURNER HEAD 9.2.6.2 INSTALLATION

9.2.6.1 REMOVAL NOTE: The burner head and exhaust outlet

port can also be aligned during installation in
1. Remove the heater (see 8.7.1.1). the vehicle.
2. Remove the combustion air fan (see 9.2.4.1).
3. Remove the burner, flame monitor and glow pin 1. Guide the burner head (1, Fig. 29) into the heat
(see 9.2.5.1). exchanger (3), align it if necessary and secure with
the V-clamping collar (2).
4. Remove the mounting screw of the V-clamping
collar (2, Fig. 29 and pull off the clamping collar. 2. If necessary, tighten the mounting screw of the
V-clamping collar to 3 Nm (26.5 lb-in) ±10%.
5. Pull out and remove the burner head (1) from the
heat exchanger (3). 3. Install the burner, flame monitor and glow pin
(see 9.2.5.2).
6. Complete the work on stripped-down components
(see 9.1.1). 4. Fit the combustion air fan (see 9.2.4.2).
5. Install the heater (see 8.7.1.2).

1 Burner head
2 V-clamping collar
3 Heat exchanger

Figure 29: Replacing the burner head

Webasto Thermo & Comfort N.A., Inc. 44 www.techwebasto.com

THERMO 90 ST REPAIR

9.2.7 REPLACING THE HEAT EXCHANGER 9.2.7.2 INSTALLATION

1. Install the burner head (see 9.2.6.2).
9.2.7.1 REMOVAL
2. Install the burner, flame monitor and glow pin
1. Remove the heater (see 8.7.1.1). (see 9.2.5.2).
2. Remove the circulating pump (see 9.2.1.1). 3. Fit the combustion air fan (see 9.2.4.2).
3. Remove the temperature limiter (see 9.2.2.1). 4. Install the temperature sensor (see 9.2.3.2).
4. Remove the temperature sensor (see 9.2.3.1). 5. Install the temperature limiter (see 9.2.2.2).
5. Remove the combustion air fan (see 9.2.4.1). 6. Install the circulating pump (see 9.2.1.2).
6. Remove the burner, flame monitor and glow pin 7. Install the heater (see 8.7.1.2).
(see 9.2.5.1).
7. Remove the burner head (see 9.2.6.1).
8. Complete the work on stripped-down components
(see 9.1.1).

www.webasto.us 45 Webasto Thermo & Comfort N.A., Inc.

REPAIR THERMO 90 ST

This page for your notes.

Webasto Thermo & Comfort N.A., Inc. 46 www.techwebasto.com

THERMO 90 ST PRODUCT INFORMATION

10. PRODUCT INFORMATION

No new or updated information available at this time.

www.webasto.us 47 Webasto Thermo & Comfort N.A., Inc.

PRODUCT INFORMATION THERMO 90 ST

This page for your notes.

Webasto Thermo & Comfort N.A., Inc. 48 www.techwebasto.com

THERMO 90 ST WARRANTY

WEBASTO LIMITED NON-TRANSFERABLE WARRANTY

Webasto Thermo & Comfort North America, Inc. (hereinafter referred to as Webasto) warrants their heaters
and heater kits against defects in material and workmanship for two (2) years effective at the time of
installation or vehicle registration date for original equipment installation (OEM). This warranty period may not
exceed three (3) years from the original date of sale by Webasto. This warranty period may be superseded by
written contractual agreements.
All models are limited to 2,000 maximum operating hours except for DBW series.
Replacement parts are covered for six (6) months or the remainder of the original warranty period, whichever is
longer. The Thermo Top C heater is the only heater considered a replacement part.
The intent of the Webasto warranty is to protect the original end-user of the heater from defects and provide
free repair and replacement of defective parts in the manner provided herein. During the warranty period, the
exclusive remedy will be for Webasto, at their discretion, to repair or replace those parts which are
demonstrated to be defective in material or workmanship.
While warranty is provided to the “original end-user”, it is to be administered and serviced through an
authorized Webasto dealer in accordance with the Webasto warranty policy or contractual agreement between
Webasto and a second party. To locate the nearest Webasto authorized dealer for warranty service, visit http://
www.webasto.com or call (800) 860-7866 in USA, (800) 667-8900 in Canada.

Limitations: Webasto specifically excludes and limits warranty from the following:
- Normal wear of service parts: (filters and fuses are not covered)
- Removal and replacement of heater (with the exception of the Thermo Top C 12 volt heater).
Note: Thermo 50 Heaters have changed from a replacement heater to a repairable heater.
- Damage to product in transit. All claims must be filed with carrier.
- Improper installation, which is not in accordance with valid, supplied installation instructions or approved
OEM applications.
- Deterioration due to normal wear, corrosion, abuse, damage, accident, improper storage or operation, lack
of reasonable and necessary maintenance.
- Modification of product by alteration, use of non-genuine parts or repair by unauthorized personnel.
- Economic loss for expenses related to travel, vehicle disability, personal injury or other incidental or
consequential damages arising from any breach of this expressed warranty.

Product registration:
The heater can be registered by visiting www.techwebasto.com or by completing the Warranty Registration
Card if included with your product. A proof of purchase is required for all heaters that are not registered.

THIS WARRANTY IS NON-TRANSFERABLE.

IMPLIED WARRANTIES INCLUDING THAT OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WARRANTY. WEBASTO DISCLAIMS
ANY LIABILITY FOR SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES.

SOME STATES AND CANADIAN PROVINCES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF
INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT
APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER RIGHTS WHICH VARY AMONG STATES AND CANADIAN PROVINCES.

WEBASTO RETAINS THE RIGHT TO MODIFY THESE WARRANTY TERMS WITHOUT NOTICE IN ORDER
TO COMPLY WITH POLICY OR LAWS GOVERNING WARRANTY ISSUES IN STATES OR COUNTRIES
HAVING SPECIFIC REMEDIES DIFFERING OR ADDITIONAL TO THOSE DESCRIBED WITHIN THIS
DOCUMENT.

www.webasto.us 49 Webasto Thermo & Comfort N.A., Inc.

 WEBASTO THERMO & COMFORT N.A., INC.
15083 North Road
Fenton, MI 48430
Technical Assistance Hotline
USA: (800) 860-7866
Canada: (800) 667-8900
www.techwebasto.com
www.webasto.us
Org. 03/2008 Rev. 11/2018 P/N LIT1301498A © 2008 Webasto Thermo & Comfort N.A., Inc.