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shaggydog

Member Since: 12 Aug 2012
Location: Kent
Posts: 3347

1991 Defender 110 200 Tdi USW Arles Blue

Good news good news!

Yesterday saw the dash stripped out so we could run the wires for the switch. I hate doing this so I left it to my very very capable assistant (to whom I owe many beers and thanks) This saw at the end of the day all of the wiring for the Webasto Fitted and a snazzy new switch fitted in the recess for what would have been the tank switch over switch.

Today started well with draping the fuel pipe and the fuel pump extension loom into place.

First issue was the extension loom was too short by exactly 12" so it was extended to fit by soldering in an extension piece.

The fuel line was then put into place and fitted to the webasto, running along the bulkhead and joining the engine fuel lines and extension loom back to the fuel tank.

The fuel pump was fitted to a suitable bracket with a hole in it and the pipes connected.

Now, here is the very clever part (i think)

Below is my high tech (HA!) drawing of how I managed to use the return for the dual tank setup as a webasto pickup!

Click image to enlarge

So basically it uses a small pipe to pick-up the fuel and then send it towards the main fuel pipe and then along to the pump.

If that makes sense, it got dark before I could take any pictures sadly.

Everything in place we put the fuse in and with some anticipation flicked the switch.

First success was that the fuse didn't blow immediately and the switch worked and the Webasto fired up into life.

I don't know if it has a purge mode or anything that sophisticated but it shut down quickly as there was no fuel in it.

We tried cycling it on letting it shut down about 4 times before my very helpful helper had to leave to go and see his wonderful missus.

The night stating to close in I decided why not give it one last go. Low and behold the air took a dieseley smell and then with a roar it started up and merrily heated away.

Fantastic!

My excitement was short lived however as it all started smelling very hot and I had to turn it off quickly as the rubber flappy thing which I had tucked the exhaust under had started to smell a bit burney so it was turned off and allowed to cool.

So just need to sort the exhaust route a bit better and then all will be finished!

Very happy! Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter

22nd Nov 2015 7:05pm

shaggydog

Member Since: 12 Aug 2012
Location: Kent
Posts: 3347

Grumble Grumble.

Got out of work today with my boss and my colleagues who all gathered round in the dark and the cold to see my new fancy webasto working having spent so long talking about it.

I turned it on, fan sped up, priming pump started and as it revved up to full power it was evident it wasn't burning anything so after a while it just stopped dead.

Paused a few seconds then tried coming on again but the fuel pump not doing anything.

Bit disappointed really and a bit embarrassed.

Any ideas what caused it?

How do I fix it? Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter

24th Nov 2015 7:36pm

Phoenix90

Member Since: 04 Mar 2012
Location: Cornwall
Posts: 377

2007 Defender 110 Puma 2.4 USW Stornoway Grey

Have you tried cycling it a few times?

Do you have a non-return valve close to the fuel tank? I think from memory, you are meant to place the fuel pump close to the tank as it acts as a non-return valve. It sounds (though it might just be the way I am reading it) though your fuel pump is quite downstream. If so, that might mean the fuel has flowed back into the tank so you are going to need to cycle it a few times to prime the fuel line?

24th Nov 2015 7:55pm

shaggydog

Member Since: 12 Aug 2012
Location: Kent
Posts: 3347

The fuel pump is about 500mm from the tank but I must admit it doesn't have a non return valve in the line, perhaps I should add one?

I must admit after 2 attempts everyone got cold and went home so I decided to follow suit and left it. Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter

24th Nov 2015 8:04pm

VeeTee

Member Since: 06 Mar 2011
Location: Somewhere
Posts: 1512

Did you turn it on while the engine was turning or with engine off? The Webasto seems very sensible for "under voltage", so if your battery voltage is not high enough it will try to start but won't glow and stop the start-up cycle just then. Have had that a few times - my Webasto is on the second battery which I had problems re charging at the time - trying again with running engine the voltage was high enough to complete the starting cycle. Cheers, Vincent
1959 Polynorm 1/4 Ton Trailer, Olive Drab Green (sold)
1970 M416 Military Trailer (Camping Trailer Conversion), Epsom Green (sold)
1975 Series III 88 V6, Light Green (sadly sold)
1996 Defender 110 CSW 300 Tdi, Epsom Green (sold)
2000 Freelander 1 TD4 3-drs, Silver (sold)
2006 Freelander 1 TD4 5-drs Facelift Automatic, Tonga Green (sold)

MySite

24th Nov 2015 8:32pm

shaggydog

Member Since: 12 Aug 2012
Location: Kent
Posts: 3347

Possibly, it was at the end of the day having driven to work in the morning and it done nothing all day. Should have had enough power though the battery is less than a year old.

I tried starting the webasto with the engine off. After it had failed twice I decided to go home and the engine started fine with no issues but if it is sensitive on voltage it may well have been that.

I just find it weird that it tried to start with the fuel pump running, didn't, then continued to run but without the fuel pump going. Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter

24th Nov 2015 8:54pm

VeeTee

Member Since: 06 Mar 2011
Location: Somewhere
Posts: 1512

^^ "then continued to run but without the fuel pump going."

I think this is normal, it just tries to finish the shut-down cycle, which is running the fan for a while to cool things down before shutting down. That is also why it is important to have it connected to an "always live" feed instead of ignition live.

Try to start the Webasto with running engine first.

Cheers, Vincent
1959 Polynorm 1/4 Ton Trailer, Olive Drab Green (sold)
1970 M416 Military Trailer (Camping Trailer Conversion), Epsom Green (sold)
1975 Series III 88 V6, Light Green (sadly sold)
1996 Defender 110 CSW 300 Tdi, Epsom Green (sold)
2000 Freelander 1 TD4 3-drs, Silver (sold)
2006 Freelander 1 TD4 5-drs Facelift Automatic, Tonga Green (sold)

MySite

24th Nov 2015 9:18pm

shaggydog

Member Since: 12 Aug 2012
Location: Kent
Posts: 3347

Ok update....

Just went out and tryed to start the webasto again.

Switched on and it went through startup, failed to start so fan stops dead and the fuel pump stops. Then fan starts up again and blows for about 3 mins-ish I didn't time it

Then it just turns off and only the circulating pump runs.

So I turned it off and then turn it back on.

Same thing happens.

I tried again but now only the circulating pump works.

What have I done

Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter

24th Nov 2015 9:27pm

shaggydog

Member Since: 12 Aug 2012
Location: Kent
Posts: 3347

Thank you Veetee for your help

I will try it with the engine running but I want to make sure it will start first.

Has it gone into lock down?

How do I reset it? Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter

24th Nov 2015 9:29pm

VeeTee

Member Since: 06 Mar 2011
Location: Somewhere
Posts: 1512

I have an Airtop, not a water heater, but I guess the error codes and reset procedure are the same, see here. Cheers, Vincent
1959 Polynorm 1/4 Ton Trailer, Olive Drab Green (sold)
1970 M416 Military Trailer (Camping Trailer Conversion), Epsom Green (sold)
1975 Series III 88 V6, Light Green (sadly sold)
1996 Defender 110 CSW 300 Tdi, Epsom Green (sold)
2000 Freelander 1 TD4 3-drs, Silver (sold)
2006 Freelander 1 TD4 5-drs Facelift Automatic, Tonga Green (sold)

MySite

24th Nov 2015 9:43pm

shaggydog

Member Since: 12 Aug 2012
Location: Kent
Posts: 3347

Just had another poke and a play.

I think it may be a fuel starvation issue so tomorrow will have a look at my dip tube and see if it is that and then work forward.

Its very annoying as it was working very well yesterday!

Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter

24th Nov 2015 11:20pm

VeeTee

Member Since: 06 Mar 2011
Location: Somewhere
Posts: 1512

Good luck!

25th Nov 2015 8:13am

JWL

Member Since: 26 Oct 2011
Location: Hereford
Posts: 3443

Might be worth checking the filter at the pump, if it's like my Eberspacher it does some peculiar things when the gauze filter under the inlet union on the pulse pump is full of crud.

25th Nov 2015 8:52am

shaggydog

Member Since: 12 Aug 2012
Location: Kent
Posts: 3347

I made a rookie error here guys.

First test run it fired up fine and worked flawlessly. I then drove to work and the problems got worse and worse with it not running, not firing being a general pain.

Then I checked the pickup tube.....dry as a bone

I had set the Pickup so that it was about 1"into the tank thinking it was empty. The tank was in fact nearly full so having driven to work it had emptied the diesel below the pickup and from that point onward any fuel pickup was not going to happen.

Longer piece of pipe fitted - bit of priming later and success!

Will upload some photos tonight of the whole setup but overall I'm really rather pleased.

Just need to build up my trust with it now

Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter

27th Nov 2015 12:59pm

VeeTee

Member Since: 06 Mar 2011
Location: Somewhere
Posts: 1512

Great! Simple solution.

27th Nov 2015 1:38pm

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