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jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8006

2011 Defender 110 Puma 2.4 USW Stornoway Grey

Thermo Top Webasto problems

Well, i knew saying last week its been in 10years and no problems would be the curse of death!

Well it appears now the thermo Top C is not well.

for info fitted to a 2.4 puma right in tight against the passenger wing to the extent you cant really even see the main unit.

after some suggestions on what i can check on it please.

So history is it stopped working on Sunday and locked itself

I reset the unit earlier today (20A fuse out).

On first fire up post reset it went through the normal cycle, burner fired up and ran for 30/40s, some initial grey smoke when it fired up which was starting to clear. (nothing too excessive but touch more than usual)

fuel pump then stopped, and it went into the shutdown process.

subsequent attempts to turn the unit on and it starts the cycle to come on, fuel pump starts but then nothing happens and it goes into shutdown again.

i believe its getting fuel - grey smoke on the initial start up and it ran on that first start up after lockout reset.

But doesnt do that since. battery voltage is fine.

any suggestions on what i can do to check further before i have to take the unit out - which is going to be a fair bit of work!

any suggestions/help creating appreciated. Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

8th Dec 2020 1:46pm

Martin
Site Admin

Member Since: 02 Apr 2007
Location: Hook Norton
Posts: 6604

2015 Defender 90 Puma 2.2 XS CSW Montalcino Red

Can you get to the 6 pin plug to get diagnostics on it?

1988 90 Td5 NAS soft top

2015 D90 XS SW

8th Dec 2020 1:59pm

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8006

not without removing the unit or taking the wing off...... Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

8th Dec 2020 2:18pm

Gillan

Member Since: 01 Apr 2016
Location: Sheffield
Posts: 35

2009 Defender 110 Puma 2.4 HT Alaska White

I had a similar problem with my thermo top on the range rover it turned out to be the glowpin which I think from memory is dual purpose it reads that the burners fired and preheats the diesel hope this helps

Gillan

8th Dec 2020 6:11pm

Badger110

Member Since: 06 Feb 2018
Location: South hams
Posts: 1039

2011 Defender 110 Puma 2.4 USW Buckingham Blue

That sucks

From what you say, it's not igniting, but i think you're already thinking along those lines as without ignition, it will power down.

Your fuel feed is from the main tank if i remember, can you check for air in the line? I'd be looking at fuel related issues before removing the unit.

I would remove the pipe from the exit side of the fuel pump when starting to check for air in the line. If no fuel is coming through then it's a possibility or it's a fuel pump failure.

I have a spare pump if you want to try that, it's old but works, just holler and i'll drop it in a jiffy bag to you

8th Dec 2020 6:44pm

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8006

Thank you for replies.

I am on the verge of ripping it out but will certainly check fuel line. Yes its from pickup dropped in from top of tank, Looked today all joints look good and couldn't see any air bubbles in the line. Can't get to connection on unit with it fitted. Also thinking fuel filter issue possibly. Is there a filter in the unit?

Will check pump end and look at pulling pipe as suggested.

Thank you all. Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

8th Dec 2020 7:11pm

Andrew james

Member Since: 02 Jan 2013
Location: Awliscombe
Posts: 88

2015 Defender 110 Puma 2.2 USW Indus Silver

James,
The fuel pump won't pump against pressure. If you have a blockage in the fuel line after the pump, it will start up, click a few times ( or may not click at all) then shut down. It may be that after a few months of not using the heater, a blockage has occurred and you need to clear the line. You can see if the pump works by disconnecting the fuel line after the pump, from the pump. If the pump then works you know the fuel line is blocked and needs clearing out.
Hope that helps,
Andrew

8th Dec 2020 7:53pm

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8006

Cheers Andrew. will check fuel line. Pump clicks and seems to supply fuel but as yet not split the line to check. it worked perfectly daily for the week leading upto the failure. in fact it been in every other day use since Sept, but fuel blockage/pump issue looks like only thing to check or can be checked really. Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

9th Dec 2020 8:31am

MadTom

Member Since: 10 Sep 2013
Location: Olomouc
Posts: 616

You can measure current draw and compare it to specifications. Glow plug takes quite a large current during start of fire in the heater.
With working glow plug and with fuel you have probably blocked the burning chamber. I had simillar problem with Webasto AirTop 2000 - the wire mesh in burning chamber was nearly full of somethnig very hard and unburnt, blocking the right fire-up. After good cleaning and with new mesh and new seals, it works nice. After that experience I have opened another two heaters and all has this problem, but a a bit less blockage, so they were still starting.
It is possible to download webasto service manuals from web. "Drobek" = The Small One - Discovery 2, "Blufínek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo

9th Dec 2020 9:05am

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8006

ok, thats sounds user serviceable, is the guide on how to strip the units online? Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

9th Dec 2020 8:42pm

Badger110

Member Since: 06 Feb 2018
Location: South hams
Posts: 1039

https://www.melloronline.co.uk/product_uploads/14417990441.pdf

Service manual breakdown.

9th Dec 2020 9:01pm

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8006

cheers, also this: https://www.experimental-engineering.co.uk...placement/ Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

9th Dec 2020 9:18pm

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8006

Well fuel line seemed ok, so have taken it out. Not a job I was looking forward to!

Click image to enlarge

Click image to enlarge Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

13th Dec 2020 10:06pm

Matt110

Member Since: 29 Jun 2014
Location: UK
Posts: 680

I feel your pain.

Literally.

Still covered in red grazes and marks from getting mine IN that hole!!! And it's not even working yet.

14th Dec 2020 11:31am

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8006

well i fitted mine in there in winter 2010 so i guess its done well not having to come out until now! Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

14th Dec 2020 6:46pm

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