Help with removing trim panel to fit Webasto heater

[Adrianlle]

Good Evening from the UK. I am about to fit a Webasto airtop 40 Evo to replace my failed Eberspacher in my 2004 Cook. I want to drill a hole in the floor so that I can pass the loom into the Cook and inside trim panels to a multi controller next to the 12 v socket on the panel above the sink area. But I cannot find a way to remove the large grey plastic panel under the side window- which I think I have to remove to drill a hole in the floor. I have removed the 4 screws at each corner and also the screws holding the table support in place. But I can’t get the panel to move.
Can someone help please and also with how to remove the steel panel above the sink so that I can pull up the loom from the hole in the floor to the new controller? Thanks. Adrian

[Thomas T.]

Hello Adrian,

please excuse my poor English.

To remove the large Panel it needs some Power. There are five or six very strong Metal-Clips on the Floor. You can see two of them in this Picture.

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You also see the Holes that I drilled for the Loom.

The Steel-Panel above the Kitchen is only screwed, maybe there is some Silicone, needs a little bit Power.

[Thomas T.]

Adrian, i forgot,

have you removed the smal, foldable Table?

[Adrianlle]

Thanks Thomas for the quick response. Your English is MUCH better than my German! I have disconnected the telescopic arm from the small table but left the arm fixed to the panel. Do I need to unscrew the arm from the panel as well? The panel feels as if it is still secured by something even though I have taken out the screws I mentioned in my post.
I see the 2 clips. So do I just use power to lift the panel upwards? I have been trying to pull it away from the outside wall- not upwards.
For the stainless steel panel, I can see 1 screw. Are there more? I am afraid of breaking something if all the screws are not removed first.

Thanks for the help. I want to get the panels etc removed before the WEbasto arrives. Adrian

[Thomas T.]

Hi Adrian,

DSCN1279.jpg (124.54 KiB) 549 mal betrachtet

the silver shining Metall-sheet holds the small Table, the Table must be removed completely.
It's right, you have to pull the Panel away from the outside wall- not upwards.

Your Metal-Panel above the Kitchen is different to mine because my Cook is much older. I'm not sure how it's fitted, but anyone other will tell us.

[Adrianlle]

Thank you Thomas. I will unscrew the small table tomorrow and try again to remove the panel! If anyone else reading this thread can tell me how to remove the stainless steel panel over the cooker/sink or the grey panel to its right on a 2004 Cook ( so that I can pull a loom from the floor into the kitchen cupboard) then I would be very grateful.
Adrian

[Adrianlle]

I am still struggling to get the grey trim panel off. It is much looser now that I have removed the small table. Do I have to take out the bench seat to give it more space for movement? If so how? Also could the heating pipes be holding the panel in place? Any help greatly appreciated? Adrian

[Thomas T.]

Hello Adrian,

at first: trying to help you is a good reason to remind the little bit of english language i learnd at school 50 years ago. So don’t hold of to ask.

I remembered that the two cupholders left and right of the smal table are also holding the trimpanel.

Here are some more pictures of the left wall without any furniture:

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I think they can help you to find the way for the wire to connect the multi controll at that place you choosed.

Removing the panel right to the sink and arround the left window need’s to remove the upper cupboard of the kittchen, not easy and lots of work! I think there is no need to do this for pulling the loom up into that cupboard.


This picture shows the multi control together with the switch of the waterboiler in my James Cook. Very comfortable on a cold morning .

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Unfortunately i couldn’t find any hint how to remove the stainless-steel panel, but i’m shure any James-Cook-friend will help you.

[Epeg]

Die Edelstahplatte ist mit 5 Schrauben unter der Küchenplatte verschraubt. Wenn die Schrauben entfernt sind, kann mann die Platte runter lassen und nach vorn ziehen.

Das ganze ist sehr fummelig und erfordert sehr viel Geduld.

Viel Erfolg

[Thomas T.]

Hi,

now i saw your last post.

Of curse the bench seat must be lifted out of it’s rails. In the front of the right rail is a smal pad screwed to the ground. Remove it and pull the seat to the front of it’s rails then lift it up, attention it’s very heavy.

The heating pipe is very flexible, you can see how it is fixed when you can look behind the panel.

[Adrianlle]

Thank you Thomas and Epeg for information on the stainless steel panel. I am v worried that if I keep pulling at the grey panel that it will split. Already there is the sign of a a beginning of a split. So I will rest a few hours and then try again !
Thomas, your multicontroller looks a good job. If I can a achieve that I will be v pleased. Was the loom from it long enough to reach the WEbasto? Adrian

[Adrianlle]

Success in getting the panel removed. I managed room get my fingers under the bottom edge of the panel and pulled hard at each clip to remove the trim. Next is the stainless steel panel. I see the screws under the work surface but as EPEG says it seems very fiddly. I am hoping that fitting the Webasto itself will be easier compared to all this trim removal! Adrian

[Thomas T.]

Hello Adrian,

congratulations, first stepps are done!

I separated the wires into two looms. One for the power supply and one for the controlunit. So it was long enough to reach the multi controll at the upper cupboard. But I think that is nonessantial

Don't worry, to change the heaters is a lot of work and not every thing is easy but you can stil manage it and it's a good feeling when the new Webasto heater does its work so much better than the old Eberspächer, and so silent.

[Adrianlle]

Thanks Thomas for the help and the encouragement. Tomorrow I take off the old Eberspacher. Two more questions if I may. First, where did you put the remote temperature sensor. There is a photo by ixcebichee showing it on an upper grey panel but I don’t know how he got that panel off to wire the sensor from behind. Secondly where did you put the Webasto fuel pump? Again there is a photo by ixcebichee showing his pump next to the heater box and not in the original position under the chassis. Maybe that was to ensure he had a long enough loom to reach the kitchen cupboard.
I intend to split the loom like you and take the power from under the drivers seat. Also, drill 2 holes like yours for the looms to the controller. Why are 2 holes needed? Is the second one for the remote temperature sensor?
Thanks again. Adrian

[Thomas T.]

Good morning Adrian,

first two pictures of my old Eberspächer heater:

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I placed the temperature sensor near the old one behind the sliding door. For connecting it to the Webasto loom i used the wires from the old sensor.

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The fuel pump i assembled in the heaterbox like it was before. There it’s well protected but it makes a low noise, not so loud as the old one but sometimes i can hear it.

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I’ve made the heater-change Eberspächer to Webasto for two times. First in November 2016 together with my friend Ralph at his James Cook and later, in March 2017 at my own. The loom, delivered by Webasto in my heaterset was very different to that in Ralph’s. After only five months! So I think planing the wiring is just possible when you hold your loom in your hands.

The two holes I drilled for later disassembling, I think two thin looms are easier to handle than one thick.

I mean the best and easyest way for power supply is to connect the original Webasto fuses direct to the batteries in the water tank, therefor you can separate the power wires from the loom near the tank. So the remaining loom may be long enough fort the controll unit.