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TSL 17 COOLANT HEATER Specifications TSL 17 Technical data is subject to +/- 10% variance Webasto TSL 17 Engine Coolant Preheating System 1. Thermo Top C Heater 2. Heated Coolant Outlet 3. Cold Coolant Inlet. Operation/Installation Manual 2 Year Limited Warranty 7-Day Digital Timer (Engine Preheat) P/N 906108A.
I installed a Webasto TSL17 in my B4 Passat and have had it running great for about 2 years now. Recently the unit has not been performing properly. I have not done any changes to the setup, so something has failed and I need some help to identify what. The unit will run the coolant circulation pump, and the combustion chamber fan on high for about one minute and then the unit will just shut off and nothing will be running except the minute count-down on the 7-day timer. The fuel pump is not audibly running during this process. The fuel pump does pump one time when connected to a 12v source. (I think this is the expected behavior.) The weird thing is that there is a constant 12v coming from the fuel pump wiring harness.
I would have expected to see a on/off cycle of current to control the fuel pump. I have reset the unit by pulling the fuse, but the problem persists. I thought I read a thread on this forum about a unit with similar symptoms, but I cannot find it now and I do not remember the solution. Do any of you Webasto gurus have any suggestions? Blowing the dust off this thread to post the solution so that maybe someone else can benefit.
Three years later I finally fixed this by taking the unit apart and scraping the carbon out of the burner assembly. Be careful with the glow plug, scrape out the large deposits with a screwdriver or pick, and be mindful not to scrape the steel wool type substance at the bottom of the burner. I should have just taken it apart 3 years ago, but the voltage at the fuel pump thew me off the trail that it was actually a lack of combustion air to the burn chamber that was the problem. That sounds about right, I found mine would not work one very cold morning, It would start then shut off after a minute or so. Found out that the exhaust out put tube had snow packed up into it.
I had backed into the garage the nigth before (There was about a 6 in fresh snow fall) and shoved snow up into the exhaust tube where it froze up that night. So you will know to check that if it will not start and run correctly. I really miss having it in this 03, if the unit was not so high I would buy another but maybe when I get done remodeling my house I can but another heater. 2003 Jetta 216 injectors, race pipe, OMI, 2.5 cat back pipe, Sachs power clutch,Lightweight fly wheel,Rocketchip 3.0,Dieselgeek race pipe,Borla SS exhaust,Dieselgeek Intercooler pipes,Pierburg MAF,EU cluster with LED Boost gauge, Ventectomy,Alientech window,Old Navy ccv filter,Catch can,Dieselgeek short shifter,ATE power slot rotors,Porterfield pads,Shine suspension,Shine rear sway bar,TT pedals & foot rest,Cat fuel filter 2 micron,Alum skid plate,Euro headlights and switch,5 Brake light mod. Blowing the dust off this thread to post the solution so that maybe someone else can benefit.
Three years later I finally fixed this by taking the unit apart and scraping the carbon out of the burner assembly. Be careful with the glow plug, scrape out the large deposits with a screwdriver or pick, and be mindful not to scrape the steel wool type substance at the bottom of the burner. I should have just taken it apart 3 years ago, but the voltage at the fuel pump thew me off the trail that it was actually a lack of combustion air to the burn chamber that was the problem.
Glad you were able to fix the unit. Well, since this thread comes up when I search the internet for how to fix my Webasto, I may as well update it with my latest update to share with the world. My method of scraping out the big chunks only seemed to get the unit to work a half dozen more times at most before it would stop again with the same symptoms I noted at the beginning of the thread. There was no solution I could find on the internet so I found someone who repairs these units professionally and actually got them to give me some advice other than to send the unit in for repair. (I was really shocked and glad when he gave real suggestions.) His suggestion was to soak the burner assembly over night in mauratic acid, rinse in water, blow it dry with compressed air, spray with brake cleaner, dry with compressed air. (Be sure to blow in the fuel inlet with compressed air.
This cleaned out a bunch for me.) He said the steel wool like wick at the bottom wasn't allowing enough fuel to pass. I blew on the fuel with my mouth before and after the cleaning and the difference was quite noticeable.
I modified the approach some. I soaked for a day in mauratic acid, rinsed with water, soaked overnight in Purple Power, rinsed with water, attempted to dry with compressed air, but my shop was so cold the water froze instead.
Therefore, I dried in the oven at the 'warm' setting. When soaking I would periodically agitate the solution and pull out the assembly to scrape any big chunks off. I always thought my glow plug was glued in. Turns out it was just carboned-in and after soaking for a bit I easily pulled it from the burner. The Webasto has started at least half a dozen times since this cleaning without issue, so I'm close to calling it a success.
Now I need to do the one in my other ride. Oh yeah, mauratic acid can typically be found in the painting section of home improvement stores in 1 gallon jugs. I think I paid about $7 for one gallon. Thanks for the update. I know from separating a thermo top C that the burner can be removed without losing coolant. Thanks for the feedback.
Wouldn't oven cleaner worked just as well a muriatic acid? Was just wondering. Sorry I didn't respond sooner. I'll respond now so this is recorded for future searchers.The TSL 17 is the same unit essentially. The way I have mine installed prevents me from separating the unit. I'm not sure if oven cleaner would be a suitable substitute.
This thread is becoming my ongoing Webasto repair thread with yearly updates. It seems like it always fails when I really need it. I picked up a used unit so I can swap them with less down time for burner cleanings. It wasn't running consistently so I thought it was time for another cleaning and I swapped in my other unit. That one ran once, but didn't ignite, and then didn't make any noises after that initial run. I found that I didn't secure one of the electrical plugs and it disconnected. Fixed that and then found it would attempt to fire but wouldn't.
It would go through the cycles which would take a few minutes, and smoke, but never warmed up. So it still wasn't igniting. Upon closer inspection, I could see air bubbles in the fuel lines move when the pump cycled. I found one loose connection, but that didn't solve it.
I got it running consistently by putting a short length of fuel hose directly into a can of diesel. I put a T in my fuel line after the diesel filter to supply the Webasto with my initial install.
It has worked for years, but if it cannot consistently draw fuel from there going forward, I will have to come up with a plan B. The car still have good power, so I don't think the filter is clogged, but that may be the easiest step to try an remedy situation. What will plan B be? Webasto recommends the pump be placed near the rear of vehicle and a draw straw into the diesel tank.
Dropping the tank to do that will wait until summer. I may try to avoid this and see if I can run a small booster pump to pull more fuel to the filter, or I may see if I can install a fuel tank just for the Webasto. Sorry I didn't respond sooner. I'll respond now so this is recorded for future searchers.The TSL 17 is the same unit essentially. The way I have mine installed prevents me from separating the unit. I'm not sure if oven cleaner would be a suitable substitute.
This thread is becoming my ongoing Webasto repair thread with yearly updates. It seems like it always fails when I really need it. I picked up a used unit so I can swap them with less down time for burner cleanings. It wasn't running consistently so I thought it was time for another cleaning and I swapped in my other unit.
That one ran once, but didn't ignite, and then didn't make any noises after that initial run. I found that I didn't secure one of the electrical plugs and it disconnected. Fixed that and then found it would attempt to fire but wouldn't. It would go through the cycles which would take a few minutes, and smoke, but never warmed up. So it still wasn't igniting. Upon closer inspection, I could see air bubbles in the fuel lines move when the pump cycled. I found one loose connection, but that didn't solve it.
I got it running consistently by putting a short length of fuel hose directly into a can of diesel. I put a T in my fuel line after the diesel filter to supply the Webasto with my initial install.
It has worked for years, but if it cannot consistently draw fuel from there going forward, I will have to come up with a plan B. The car still have good power, so I don't think the filter is clogged, but that may be the easiest step to try an remedy situation. What will plan B be?
Webasto recommends the pump be placed near the rear of vehicle and a draw straw into the diesel tank. Dropping the tank to do that will wait until summer. I may try to avoid this and see if I can run a small booster pump to pull more fuel to the filter, or I may see if I can install a fuel tank just for the Webasto. I'm sure you've seen those of us drill our fuel sending unit with an included pick up that comes with the install kit.
The 12v pump mounts near the rear driver's lift pad hole just before the rear torsion bar. I bought a cleaning kit but it turned out to be my thermostat which was bad. Webasto works fine now.
. – Installation and repair of Webasto heating and cooling systems requires special Webasto training, technical information, special tools and special equipment. – NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills, technical information, tools and equipment required to properly complete the necessary procedures. 7.2 Thermo 90 ST Circuit Diagram Legend.21 www.webasto.us Webasto Product N.A., Inc.
Replacing the Heat Exchanger.41 Webasto Product N.A., Inc. 9.2.7.2 Installation.41 10.Product Information www.webasto.us Webasto Product N.A., Inc.
TABLE OF CONTENTS THERMO 90 ST Webasto Product N.A., Inc. The same applies if repairs are Any special safety regulations relevant to this instruction carried out incorrectly or with the use of parts other than manual will be highlighted in the relevant sections or text genuine spare parts. 1.5 S UGGESTIONS FOR MPROVEMENTS AND HANGES Complaints, improvement suggestions or corrections relating to this workshop manual should be addressed Webasto Product North America, Inc. Technical Documentation Group 15083 North Road Fenton MI 48430 Phone: 810.593.6000 PC-Fax: 810.593.6135 Webasto Product N.A., Inc.
2 hours after the heater is switched on. Combustion air fan Fuel connection Temperature sensor Temperature limiter Heat exchanger Inlet, coolant Circulating pump Outlet, coolant Outlet, exhaust gas 10 Inlet, combustion air 11 Control unit Figure 1: Thermo 90 ST heater www.webasto.us Webasto Product N.A., Inc.
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. Webasto Product N.A., Inc. 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 www.webasto.us Webasto Product N.A., Inc. GENERAL DESCRIPTION THERMO 90 ST This page for your notes. Webasto Product N.A., Inc.
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.
Www.webasto.us Webasto Product N.A., Inc. Flame monitor take-over Stabilization time Stabilization time Coolant temperature reduced Full load Full load Vehicle fan “On” Switch off (run-on) Control range Flame monitor “Cold” (0) Control pause Run-on ended (cool-down) Flame monitor “Cold” (0) Webasto Product N.A., Inc. Temperature sensor interrupt or temperature sensor short circuit Metering pump interrupt or metering pump short circuit Fan motor interrupt or fan motor short circuit or fan motor incorrect speed Glow pin interrupt or glow pin short circuit Overheating www.webasto.us Webasto Product N.A., Inc. FUNCTIONAL DESCRIPTION THERMO 90 ST This page for your notes. Webasto Product N.A., Inc. 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. TECHNICAL DATA THERMO 90 ST HEATER Operation THERMO 90 ST B THERMO 90 ST D In Exhaust Gas Maximum 10. 12.0% by volume (permitted function range) adjustment values at approx. +20 °C Maximum 0 m (0 ft) 500 m (1640 ft) 1000 m (3280 ft) 10.6%. 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. Check cabling for damage, discontinuity and (flame monitor defective) short-circuit Flame monitor defective Replace flame monitor Flashing pulses Cabling Check cabling for damage, discontinuity and (temperature sensor short-circuit defective) Temperature sensor defective Replace temperature sensor Page 1 of 2 Webasto Product N.A., Inc. F 09 Ceramic glow pin possible.
Switch heater on. F 10 Overheat condition F 11 Coolant circulating pump Contact a Webasto service facility if heater operation cannot be restored. F 02 Flame failure After 6 consecutive attempts, heater and control unit are locked out. 1.5 mm or 1/16 in. Diameter wire).
Remove the glow pin first. 1 Fuel pipe 2 Round seal 3 Flame monitor 4 Insulation 5 Glow pin 6 Housing 7 Screw 8 Bar 9 Start air hole Figure 10: Visual check, burner back wall Webasto Product N.A., Inc. The insulation (item 4, Fig. 10) must not be missing. Pilot flame outlet opening Air swirl plate Combustion chamber 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 www.webasto.us Webasto Product N.A., Inc.
TROUBLESHOOTING THERMO 90 ST This page for your notes. Webasto Product N.A., Inc.
Test current.