Eberspächer HYDRONIC S3 D 5 E Installation Recommendations
VEHICLE HEATERS | TECHNICAL DOCUMENTATION
INSTALLATION RECOMMENDATION
EN
HYDRONIC S3 – D 5 E IN THE FORD F 250/ F 350
SPARE PARTS LIST
REPAIR INSTRUCTIONS
TECHNICAL DESCRIPTION
INSTALLATION RECOMMENDATIONS
THIS INSTALLATION RECOMMENDATION APPLIES TO VEHICLES FROM MODEL YEAR 2016 WITH
THE FOLLOWING MOTORISATION:
6.7 l cubic capacity / 8 cylinder V-engine / 328 kW - 446 HP (HSN: 1028)
A WORLD OF COMFORT
VEHICLE HEATERS – TECHNICAL DOCUMENTATION | 2
CONTENTS
CHAPTER CHAPTER DESCRIPTION PAGE
1 Introduction 3-5
2 Preparation of the vehicle 6
3 Preliminary assembly 7-12
4 Installation 13-30
5 After installation 31
6 Parts overview 32
7 Initial commissioning EasyStart Timer, Remote, Remote+ 33-40
8 Diagnostics 41
Leaflet for the Customer 43
This installation recommendation documents the installation of the Hydronic S3 heater in a vehicle from model year
2016 with the following equipment:
with 2-zone automatic AirCon
with fog lamps
with daytime running lights
with LED headlights
with automatic gearbox
with four-wheel drive 4 x 4 on demand
not tested:
manual air-conditioning
PLEASE NOTE!
This installation recommendation is valid for the above mentioned vehicle to the exclusion of all liability claims.
Deviating model years and/or deviating equipment may result in modifications to this installation recommendation.
It is therefore mandatory to check the feasibility of installing the heater in the vehicle before starting work.
All liability claims resulting from modifications to the vehicle are excluded.
Installation time: approx. 8 hours
1 INTRODUCTION
VEHICLE HEATERS – TECHNICAL DOCUMENTATION | 3
SPECIAL TEXT FORMATS, PRESENTATIONS AND PICTURE SYMBOLS
In this installation recommendation, special text formats and picture
symbols are used to emphasise different contents. Please refer to the
following examples for their meanings and appropriate action.
SPECIAL TEXT FORMATS AND PRESENTATIONS
This dot () denotes a list, which is started by a heading.
– If an indented dash (–) follows a “dot”, this list is a sub-section of
the black dot.
PICTURE SYMBOLS
DANGER!
This information points out a potential serious or fatal danger. Ignoring
this information can result in severe injuries.
Î This arrow indicates the appropriate precaution to take to avert the
danger.
CAUTION!
This information points out a dangerous situation for a person and / or
the product. Ignoring this information can result in injuries to people
and / or damage to equipment.
Î This arrow indicates the appropriate precaution to take to avert the
danger.
PLEASE NOTE!
These remarks contain recommendations for use and useful tips for the
operation, installation and repair of the heater.
SAFETY INSTRUCTIONS FOR INSTALLATION AND REPAIR
DANGER!
Improper installation or repair of Eberspächer heaters can cause a fire
or result toxic exhaust entering the inside of the vehicle.
This can cause serious and even fatal risks.
Î Only authorised and trained persons may install the heater accord-
ing to the specifications in the technical documents or repair it
using original spare parts.
Î Installation and repairs by unauthorised and untrained persons,
repairs using non-original spare parts and without the technical
documents required for installation and repair are dangerous and
therefore are not permitted.
Î Installation according to this installation recommendation may only
be carried out in conjunction with the respective unit-related tech-
nical description, installation instructions, operating instructions
and maintenance instructions.
This document must be carefully read through before / during in-
stallation and repair and followed throughout. Particular attention is
to be paid to the official regulations, the safety instructions and the
general information.
PLEASE NOTE!
The relevant rules of sound engineering practice and any information
provided by the vehicle manufacturer are to be observed during the
installation and repair.
When carrying out electric welding on the vehicle, the positive cable
at the battery should be disconnected and earthed to protect the
control box.
LIABILITY CLAIM / WARRANTY
Eberspächer does not accept any liability for defects and damage,
which are due to installation or repair by unauthorised and untrained
persons.
Compliance with the official regulations and the safety instructions is
prerequisite for liability claims.
Failure to comply with the official regulations and safety instructions
leads to exclusion of any liability of the heater manufacturer.
ACCIDENT PREVENTION
General accident prevention regulations / health and safety regulations
and the corresponding workshop, company and operating safety in-
structions are to be observed.
1 INTRODUCTION
VEHICLE HEATERS – TECHNICAL DOCUMENTATION | 4
ADDITIONAL INFORMATION ON THE VALIDITY OF THE INSTALLATION
RECOMMENDATION
The installation recommendation is valid for the vehicle with the engine
and gearbox options listed in the following.
ENGINE AND GEARBOX OPTIONS
Cubic capacity kW / HP Gearbox
6.7 l 328 / 446 AT
AT = automatic transmission
PLEASE NOTE!
The installation recommendation is not valid for right-hand drive
vehicles.
Vehicle models, engine types and feature options not listed in this
installation recommendation, have not been tested.
Installation according to this installation recommendation can still be
possible.
INITIAL STARTUP OF THE HEATER OR FUNCTIONAL TEST
After installation or carrying out a repair on the heater, the coolant
circuit and the whole fuel supply system must be carefully vented.
Comply with the instructions issued by the vehicle manufacturer.
Open all heating circuits before the trial run (set the temperature
controller to “hot”).
During the heater trial run, all water and fuel connections must be
checked for leaks and secure, tight fit.
If faults occur while the heater is running, use a diagnostic unit to
correct the cause of the fault.
PARTS REQUIRED FOR INSTALLATION
QUANTITY DESIGNATION ORDER NO.
1 Hydronic S3 - D 5 E VDP 25 2921 05 00 00
1 Vehicle-specific installation kit 24 8000 35 00 34
EasyStart control unit as chosen:
1 EasyStart Timer 22 1000 34 15 00
1 EasyStart Remote
1
Easy Start Remote
+
22 1000 34 17 00
22 1000 34 23 00
SPECIAL TOOLS REQUIRED
Necessary torque wrench
Blind rivet nut insertion tool
Anti-corrosion agent
Crimping tool
Pliers for spring band clamps
TIGHTENING TORQUES
If no tightening torques are specified, tighten the screw connections
according to the following table:
Part name Tightening torques
+0.5
+0.5
+1
+0.5
+0.5
+0.2
+1
+2
+2
+1
+0.5
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Hex screw M6 10
Hex screw M8 20
Hex screw M10 45
Self-tapping M6 x 16 Torx screw 11
Screw M4 3
Screw M5 x 10 5
Screw M5 x 18 6.5
Pipe clip for exhaust pipe 7
Hose clip for water hose 3
Hose clip for combustion air pipe 5
Hose clip for fuel pipe 1
1 INTRODUCTION
INSTALLATION DRAWING
VEHICLE HEATERS – TECHNICAL DOCUMENTATION | 5
8
6
7
2
5
1 Heater Hydronic S3
2 Water pump
3 Exhaust pipe with exhaust silencer
4 Combustion air tube
5 Fuse holder
6 Fan control box “EasyFan”
7 Stationary part EasyStart Remote / Remote+
8 Button EasyStart Remote / Remote
+
9 Metering pump
10 Fuel tank extractor
10
1
9
4
2 PREPARATION OF THE VEHICLE
PREPARATORY WORK ON THE VEHICLE
VEHICLE HEATERS – TECHNICAL DOCUMENTATION | 6
Disconnect the battery
Remove the aircon control
Remove the left lower trim moulding of the instrument panel
Remove lower gearbox cowling
Remove front right-hand wheel
Instructions for removing the AIRCON CONTROL
(see photos 1 and 2)
Take the upper shelf up and out of the instrument panel.
Unscrew the two fastening screws from the cover of the radio / aircon
control.
Remove right-hand, front wheel arch liner
Remove tank according to the manufacturer's instructions
Depressurise the cooling system
Drain coolant into a clean container
a
b
Fig. 1
a Take shelf out of the instrument panel
b 2 x fastening screws
Use a plastic wedge to release the cover of the radio/aircon control out
to the back of the instrument panel.
Disconnect the electric plug from the aircon control.
a
Fig. 2
a Take cover of radio/aircon control out to the back of the instru-
ment panel
3 PRELIMINARY ASSEMBLY
PREPARE HEATER
(see photos 3 and 4)
Mount the angled water connection socket to the heater as shown, see
“Assembly Steps”.
VEHICLE HEATERS – TECHNICAL DOCUMENTATION | 7
Remove the duplicate nameplate from the heater.
Installation steps
Grease the O-ring (5) and insert in the groove at the connection
socket.
Fit the connection socket (3 or 4) in the cut-outs of the sensor cover
(2). The collar of the connection socket is above the cover.
Position the connection socket with the gearing in the sensor cover
and fix accordingly.
Fit the sensor cover on the heater with the connection socket point-
ing forwards.
Press the connection socket completely into the corresponding holes
on the heat exchanger.
Adjust the direction for the angled connection socket:
– Raise the sensor cover up to the collar of the connection socket
– Turn the connection socket in the required direction
– Push the sensor cover down and readjust the position of the con-
nection socket so that the toothed edges engage again
Fasten sensor cover with M5 x 18 (1) screw
(tightening torque 6.5
+0.5
Nm).
a
Fig. 3
a Heater
b Mount elbow connection
b
Fig. 4
1 M5 x 18 screw 4 Angled connection socket
2 Sensor cover 5 O-ring
3 Connection socket, straight
3 PRELIMINARY ASSEMBLY
ADHERE DUPLICATE NAMEPLATE
(see photo 5)
Fit the duplicate nameplate on the B-pillar on the driver's side as
shown.
VEHICLE HEATERS – TECHNICAL DOCUMENTATION | 8
Fig. 5
a Fit duplicate nameplate
a
a
PREPARE UNIT BRACKET
(see photo 6)
Keep the unit bracket ready for subsequent installation.
PREMOUNT WATER PUMP
(see photo 7)
Insert the water pump in the water pump holder.
a
Fig. 6
a Unit bracket
b
Fig. 7
a Holder, water pump
b Water pump
a
1400
25
60
25
60
440
25
3 PRELIMINARY ASSEMBLY
960
25
60
25
PREPARE WATER HOSES
(see photos 8 and 9)
The water hoses are already prepared as shown.
from engine (return line) to water pump
Water pump
Water hose 1
Heat-shrink fit hose
Ø 40/20 mm, L = 390 mm
VEHICLE HEATERS – TECHNICAL DOCUMENTATION | 9
Reducer
Ø 20/18 mm
Heater
Heater
Water hose 2
from water pump to heater
Heat-shrink fit hose
40/20 mm Ø, L = 910 mm
Water hose 3
from heater to engine
Heat-shrink fit hose
40/20 mm Ø, L = 1350 mm
Engine
(oil cooler outlet)
Water pump
Reducer
Ø 20/18 mm
Fig. 8
Engine
3 PRELIMINARY ASSEMBLY
Water hoses 1 to 3 in the installation kit are prepared as shown in
Figures 8 and 9.
VEHICLE HEATERS – TECHNICAL DOCUMENTATION | 10
a
b
c
Fig. 9
a Water hose 1
b Water hose 2
c Water hose 3
PREPARE EXHAUST SILENCER
(see photo 10)
Prepare the already premounted exhaust silencer for subsequent
installation.
Shape the exhaust pipe end as shown.
PREMOUNT METERING PUMP
(see photo 11)
Insert the metering pump in the rubber holder as shown in the photo.
a
b
Fig. 10
a Premounted exhaust silencer
b Shape exhaust pipe end
a
Fig. 11
a Insert metering pump in rubber holder
3 PRELIMINARY ASSEMBLY
PREPARE FUEL PIPE (SUCTION LINE)
(see photo 12)
Prepare the premounted fuel pipe (suction line) with 105° fuel hose
elbow and 3.5 x 3 mm Ø fuel hose for subsequent installation.
VEHICLE HEATERS – TECHNICAL DOCUMENTATION | 11
105° fuel hose elbow Fuel hose 3.5 x 3 mm Ø
a
Fig. 12
a Fuel pipe (suction line)
PREPARE FUEL PIPE (PRESSURE LINE)
(see photo 13)
Fit the 4.5/3.5 mm Ø adapter to the fuel pipe (pressure line) with a
9 mm Ø clip and keep ready for subsequent installation.
Mount the 4.5/3.5 mm Ø adapter to the fuel connection of the heater.
PREPARE FUSE BLOCK
(see photo 14)
Prepare the premounted holder with fuse block and diagnostic connec-
tor for subsequent installation.
Fuel hose 3.5 x 3 mm Ø
b
Fig. 13
a Mount fuel pipe (pressure line) with 4.5/3.5 mm Ø adapter
b Fuel hose 3.5/3 mm Ø
Fuel hose 4.5 x 3.5 mm Ø
a
a
Fig. 14
a Fuse block and plug holder with diagnostic connector already
premounted to holder
3 PRELIMINARY ASSEMBLY
PREMOUNT STATIONARY PART OF THE EASYSTART REMOTE+ AND EASY-
FAN FAN CONTROL BOX
(see photo 15)
VEHICLE HEATERS – TECHNICAL DOCUMENTATION | 12
b
Mount the stationary part of the EasyStart Remote/Remote+ and the
EasyFan fan control box to the 90° angle bracket (22 9000 52 00 69)
using two M4 x 10 screws as shown.
PREMOUNT SECOND WATER PUMP FOR HEAT EXCHANGER CIRCUIT
(see photo 16)
Insert the second water pump for the heat exchanger circuit in the wa-
ter pump holder.
a
c
Fig. 15
a 90° angle bracket
b Stationary part EasyStart Remote/Remote+
c Fan control box “EasyFan”
b
Fig. 16
a Holder, water pump
b Water pump
a
4 INSTALLATION
PREPARE THE INSTALLATION POSITION
(see photos 17 and 18)
The installation position is on the left-hand side at the crossbeam
behind the gearbox when viewed in the direction of travel.
VEHICLE HEATERS – TECHNICAL DOCUMENTATION | 13
108
17
Mark the first point for drilling in the dimensions as shown and drill a
9 mm Ø hole.
Insert an M6 blind rivet nut into the drilled hole.
Hold the unit bracket at the drilled hole, align horizontally and mark the
other three drilling points.
Drill the three holes with 9 mm Ø and insert an M6 blind rivet nut in
each hole.
CAUTION!
Deburr all drilled holes and treat with anti-corrosion agent.
a
Fig. 17
a Mark drilling point and drill 9 mm Ø hole
a
MOUNT HEATER HOLDER
(see photo 19)
Fit the heater holder to the M6 blind rivet nuts using four M6 x 16
screws as shown.
Fig. 18
a Mark three more drilling points and drill three more 9 mm Ø holes
a
Fig. 19
a Mount heater holder with four M6 x 16 screws
4 INSTALLATION
VEHICLE HEATERS – TECHNICAL DOCUMENTATION | 14
INSTALL HEATER
(see photo 20)
Install the heater in the unit bracket as shown and fasten to the unit
bracket using a self-tapping M6 x 16 mm Torx screw.
LAY COMBUSTION AIR PIPE
(see photos 21 and 22)
Connect the combustion air pipe to the heater using a 16 - 25 mm Ø
hose clip.
b
b
a
Fig. 20
a Heater
b Self-tapping M6 x 16 mm Torx screw
b
Lay the combustion air pipe to the front into the protected area above
the left-hand vehicle frame.
CAUTION!
Lay the combustion air silencer so that only clean, dry combustion air
can be drawn in through the heater.
a
Fig. 21
a Heater
b Connect combustion air pipe
a
Fig. 22
a Lay combustion air pipe
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