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Observations from FBH service/R&R
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kayble
 


Member Since: 01 Aug 2015
Location: Merseyside
Posts: 124

United Kingdom 2005 Discovery 3 TDV6 S Manual Java BlackDiscovery 3
Observations from FBH service/R&R

Hello,

I own an '05 TDV6 S Discovery 3 on 117k miles. The FBH was inop - attemping to start but failing with a small amont of smoke, and no sustained burn.

I followed Robbie's R&R service guide, just wanted to post some thoughts:

I used a an old tootbrush and some brake cleaner; I ended removing this much crud from the burner housing and the burner itself:

Click image to enlarge


Exhaust pipe was similarly crudded up - ended up with a similarly sized pile from that as well.

I knew full well that one of the connectors was a pain to get off; that in Robbies thread someone had already reported snapping the socket of the PCB cover - and still I went ahead and did myself - Censored

Affected a repair with 2-part epoxy:

Click image to enlarge


Click image to enlarge


Notes for anyone else doing this job for the first time:
1. R&R of the unit may appear to be self explanatory from Robbie's guide; maybe I was niaive but I judged that you get the whole unit plus the exhaust up and out from above. Sadly that isn't possible and I ended up having to take the wheelarch liner off to separate the FBH from the exhaust from underneath.
2. This is the picture you want to use in order to orient the coolant inlet/outlet pieces correctly during re-assembly:

Click image to enlarge


3. Presuming you have access to the Webasto Thermo Test software and relevant cables; you probably don't need to prime the burner for 60 seconds. I honestly don't know how long one should prime the system for once all put back to gether - but my WTT software had a default value of 60 seconds. This meant that I gassed my entire street on the first start up!

4. with new o-rings, the plastic outlets coolant are quite tight to reinstall correctly without unseating the o-ring. I used a tiny slip of contact grease to aid re-assembly.


The FBH is now back on the car and running, apparently, reliably.

Some other pics of the process for me:

Burner housing prior to cleaning:

Click image to enlarge


And after cleaning:
Click image to enlarge


The gasket set from LR:
Click image to enlarge


Does anyone know the meaning of the 'heating energy' bar in the WTT operating indicators readout below:

Click image to enlarge


It tailed off as the FBH was burning, down to zero - even though the flame detector was reporting a sustained burn and coolant was increasing in temperature within the unit?
  
Post #194765123rd May 2018 9:46 pm
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ClassikFan
 


Member Since: 02 Nov 2016
Location: Surrey
Posts: 833

United Kingdom 2008 Discovery 3 TDV6 SE Auto Stornoway GreyDiscovery 3

Just found your thread, I too am having trouble with the same electrical connector and cannot release it whilst trying not to be heavy handed and break it. Is there any hints you can give on how to do it, please?
 Just 'cause you got the power... that don't mean you got the right.
 
 
Post #20249803rd Feb 2019 8:21 am
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Bodsy
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Member Since: 06 Nov 2006
Location: In the Clubhouse
Posts: 21329

United Kingdom 2007 Discovery 3 TDV6 HSE Auto Java BlackDiscovery 3

I use a screwdriver in the gap you see
You need to get the bit of plastic to lever outwards to release the clip, so you actually move the screwdriver towards the Fbh not towards the battery.
Sometimes you need to push the connector in a touch to relieve pressure whilst you release the clip and can then slide it out.
 Bodsys Brake Bible

D4/D3 Remote FBH heat kits
BAS Remaps/ EGR Blank
Transmission Flush
Software updates/enabling


Clock/ SNOTM /3Flash / 4x4Info /BT Update /Service Reset/Error Codes / Gearbox Reset
See It Here 
 
Post #20249953rd Feb 2019 8:57 am
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ClassikFan
 


Member Since: 02 Nov 2016
Location: Surrey
Posts: 833

United Kingdom 2008 Discovery 3 TDV6 SE Auto Stornoway GreyDiscovery 3

Thanks Bodsy. Off without breaking but took a while!





 Just 'cause you got the power... that don't mean you got the right.
 
 
Post #20250423rd Feb 2019 11:30 am
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kayble
 


Member Since: 01 Aug 2015
Location: Merseyside
Posts: 124

United Kingdom 2005 Discovery 3 TDV6 S Manual Java BlackDiscovery 3

In my case, I gave up on disconnecting that troublesome connector from the FBH - and spliced in an easily accessible connector like so:

Click image to enlarge



To remove the FBH, you disconnect the accesible connectors, and then this new connector - without needing to disturb the original troublesome connector on the FBH PCB.

THe white wire off the loom in the picture is one of the control wires for the FBH controller, need to tidy that up when the weather is better.
  
Post #20265818th Feb 2019 8:21 am
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