Continue to chase the gremlins in my Webasto.

Cold weather operation was restored. It was the electrode gap that was not on the right spot in the fuel stream. So even though I could see arcing and I could see the fuel spray, the arc needs to be in the perfect spot within the fuel spray for ignition to take place. It was rookie mistake on my part as I set the electrode gap tool on the nozzle and it needed to be on the nozzle holder. That put the electrodes a little further from the fuel nozzle than they needed to be. I adjusted that and Webasto started working just fine - in cold ambient temperatures.

Now into the second part. I know the problem is with the ignition module. Using the tester, I can see that the ignition module doesn’t fire when the ambient temperature is above about 50 degrees. I removed the ignition module from the top of the motor housing to check if there was 24 volt to the ignition module. Interestingly, when I removed the 4 screws to the ignition module, the ignition started working and Webasto worked in 60 plus degrees ambient temperature. I put the ignition module back on with all 4 screws, and it stopped working again. So as of today, the ignition works when the module is not screwed on and stops working as soon as I tighten all 4 screws. I know I need to change ignition module. The electrical engineer in me wants to make sense out of it so I am going to play some more with different iterations of screws and ignition module install. It is not pinching the two wires when tightened, so that’s not the cause. It can’t be motor vibration as vibrations are same at all temperatures.

Will keep posting results for reference.

Regards, Shahzad