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Webasto Thermo Top Evo 5+, Инструкция по установке

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Mercedes Benz  C-Class S204, W204, C204 / GLK-Class X204 

Ident. No.:  1315959G_EN

 

Status: 31.01.2013

© Webasto Thermo & Comfort SE

2

Estate Car (S204):

GLK (X204):

Motorisation

Fuel

Transmission type Output in kW

Displacement in cm³ Engine code

C 180 K

Petrol / R4

AT / SG

115

1796

271.952/ .910

C 180 CGI

Petrol / R4

AT / SG

115

1796

271.820

C 200 K

Petrol / R4

AT

135

1796

271.950

C 200 CGI

Petrol / R4

AT / SG

135

1796

271.820

C 230

Petrol / R4

AT

150

2496

272.921

C 250 CGI

Petrol / R4

AT

150

1796

271.860

C 280

Petrol / V6

AT

170

2996

272.947

C 300

Petrol / V6

AT

170

2996

272.947

C 350 CGI

Petrol / V6

AT

200
225

3498

272.961
276.957

C 180 CDI

Diesel / R4

AT / SG

88

2143

651.913

C 200 CDI

Diesel / R4

AT / SG

100

2143

646.811

C 220 CDI

Diesel / R4

AT / SG

125

2143

651.911/646811

C 250 CDI

Diesel / R4

AT / SG

150

2143

651.911/ .912

C 300 CDI

Diesel / R4

AT

170

2987

642.832/ .830

C 320 CDI

Diesel / V6

AT

165

2987

642.960/ .961

C 350 CDI

Diesel / V6

AT

165
170
195

2987

642.960/ .961
642.832/ .830
642.834

Motorisation

Fuel

Transmission type Output in kW

Displacement in cm³ Engine code

GLK 280

Petrol / V6

AT

170

2996

272.948

GLK 350

Petrol / V6

AT

200
225

3498

272.971/ .991
276.957

GLK 320 CDI

Diesel / V6

AT

165

2987

642.961

GLK 350 CDI

Diesel / V6

AT

165
170
195

2987

642.961
642.832
642.835

AT = 7G - Tronic
SG = Manual transmission

From Model Year 2007
Left-hand drive vehicle

Verified equipment variants:

Automatic air-conditioning
Blue Efficiency / Blue Tec / 4 Matic
Headlight washer system

Not verified:

AMG 950 Sports Package
AMG Optical package

Exclusion:

C 63 AMG
GLK 200/220/250 CDI

Total installation time:

approx. 8 hours

Содержание Thermo Top Evo 5+

Страница 1: ...5 2143 651 911 C 250 CDI Diesel R4 AT SG 150 2143 651 911 912 Motorisation Fuel Transmission type Output in kW Displacement in cm Engine code C 180 K Petrol R4 AT SG 115 1796 271 952 910 C 180 CGI Petrol R4 AT SG 115 1796 271 820 C 200 K Petrol R4 AT SG 135 1796 271 950 C 200 CGI Petrol R4 AT SG 135 1796 271 820 911 C 230 Petrol R4 AT SG 150 2496 272 911 921 C 250 CGI Petrol R4 AT 150 1796 271 860...

Страница 2: ...646 811 C 220 CDI Diesel R4 AT SG 125 2143 651 911 646811 C 250 CDI Diesel R4 AT SG 150 2143 651 911 912 C 300 CDI Diesel R4 AT 170 2987 642 832 830 C 320 CDI Diesel V6 AT 165 2987 642 960 961 C 350 CDI Diesel V6 AT 165 170 195 2987 642 960 961 642 832 830 642 834 Motorisation Fuel Transmission type Output in kW Displacement in cm Engine code GLK 280 Petrol V6 AT 170 2996 272 948 GLK 350 Petrol V6...

Страница 3: ...formation 5 Explanatory Notes on Document 5 Preliminary Work 6 Heater Installation Location 6 Preparing Electrical System 7 Electrical System 8 Fan Control 9 Mounting Push Button 12 Telestart 13 Preparing Installation Location 14 Mounting Heater 16 Exhaust Gas 17 Fuel 19 60L Fuel Tank Metering Pump 21 80L Fuel Tank Metering Pump 22 Petrol Fuel Standpipe 23 Diesel Fuel Standpipe 26 Connecting Meter...

Страница 4: ...om 29 04 2009 and should also be observed in countries in which there are no special regulations Important Failure to follow the installation instructions will result in the invalidation of the type approval for the heater and therefore invalidation of the general homologation of the vehicle Note For vehicles with an EU permit no entry in accordance with 19 Sub Section 4 of Annex VIII b to the Roa...

Страница 5: ...rom model year 2008 for validity see page 2 assuming technical modifications to the vehicle do not affect the installation any liability claims excluded Depending on the vehicle version and equipment modifications may be necessary during installation with respect to this installation documentation Vehicle and engine types equipment variants and other specifications not listed in this installation ...

Страница 6: ...ain off the engine coolant according to the manufacturer s instructions Remove the lower right vehicle trim Remove the front right hand wheel Remove the front right hand wheel well trim Remove right underbody trim Remove seat of rear bench seat detach screw fitting 1x in cup holder C coupe only Open the right hand tank fitting service lid Detach the fuel tank sending unit on the right as described...

Страница 7: ...eparing Electrical System Detach 6mm dia cable lug 1 Preparing wiring har ness of fan control IPCU view on contact side The pre programmed settings are to be checked during function control and adjusted if necessary Duty cycle 56 62 Frequency 400Hz Voltage 3 0V Function High side IPCU view 2 1 86 85 E A IPCU A 15 86 85 E ...

Страница 8: ... 1 if original vehicle wiring harness is not available 3 Wiring harnesses of heater and heater control Wiring har ness rout ing diagram Fuse holder of engine compartment Replace F2 with 1 A fuse 1 5mm dia hole M5x16 bolt washers 2x re taining plate of fuse holder nut 2 F1 2 fuses mounted Positive wire Manufacturer installs different positive support points Connect power supply of heater 1 to pos i...

Страница 9: ...positioning module bl blue F fuse ge yellow K1 Fan relay ST 4 Connector 4 pin KB br brown K2 Additional relay gn green F1 Fuse 20A F2 30A fuse replaced with 1A IPCU Pulse width modulator IPCU adjustment values Duty cycle 56 62 Frequency 400Hz Voltage 3 0V X Cutting point Function High side Wiring colours may vary Webasto 31 30 15 Mercedes HG X2 1 2 X1 5 2 F2 F1 gn ws 0 75 ge 0 5 rt sw 0 5 rt 4 br ...

Страница 10: ...ith cable ties Produce connections as shown in wiring diagram 1 Original vehicle stud bolt original vehicle earth wires 2 Angle bracket 3 M5x16 bolt washer flanged nut 4 IPCU socket 6 Relay socket Mounting relay sock et and IPCU socket Install green white gn ws wire 1 in the IPCU 86 socket Produce connections as shown in wiring diagram 2 Brown br wire of heater wiring har ness 3 Brown br wire of f...

Страница 11: ...ng A C control panel Connection to 4 pin connector 3 from A C control panel Produce connections as shown in wiring dia gram 1 Blue bl wire K2 30 2 Red rt wire of flap positioning module 4 Red rt wire of 4 pin KB connector 5 Blue bl wire K2 87 Connect ing A C control panel Connection to plug in connector 3 of socket outlet lighter Produce connections as shown in wiring diagram 1 Red rt wire K1 86 2...

Страница 12: ...be installed in the trim piece due to parts lying behind it the in stallation is done according to image 19 1 Cover Removing cover Mount union nut 1 of push button align in centre and drill 16mm dia hole 2 in the cover stepped drill bit Hole in cov er Install push button 1 align and secure it with union nut Mounting push but ton When drilling watch components located be hind 1 12mm dia hole Hole f...

Страница 13: ...asto Thermo Comfort SE 13 1 Cover Removing cover Alternative installation location Only in connection with Telestart Use wiring harness extension 1 12mm dia hole push button Mounting push but ton Telestart 1 Receiver adhesive tape Mounting receiver 1 Antenna Mounting antenna 18 1 19 1 1 20 21 1 ...

Страница 14: ... and fix with cable tie observe dis tance between connector of front fog light if available and bracket of heater Detaching bracket Remove joint sealer in the area of the holes 1 or 2 on the inner side of the frame side mem ber C204 S204 and W204 1 7 mm dia hole X204 2 7 mm dia hole Hole in frame side member Figure shows W204 with daytime running light Mount heating bracket 3 with oblong hole be t...

Страница 15: ...ed nut Loosely mounting heater S204 W204 and X204 with daytime run ning light 1 Copy 7 mm dia hole pattern Copying hole pat tern S204 and W204 with front fog light Ensure proper spacing between connector of front fog light 3 and bracket of heater 1 at least 5mm 2 Copy 7 mm dia hole pattern Copying hole pat tern X204 with front fog light 1 Copy 7 mm dia hole pattern Copying hole pat tern 26 1 27 1 ...

Страница 16: ...ime running light Mount bracket of heater 1 on bolt 3 insert be tween detached bracket and bumper Align heater and fasten at position 4 and 6 Tighten original vehicle bolt at position 5 Tighten bolt 4 on retaining strut 2 Flanged nut 6 M6x20 bolt flanged nut Mounting heater Figure shows X204 with front fog light Mount bracket of heater 1 on bolt 3 between detached bracket and bumper Insert 8 mm sh...

Страница 17: ...aust pipe Mount exhaust silencer 3 on exhaust pipe 1 and align relative to hole 4 Mount wiring har ness 5 on heater 2 Hose clamp Premount ing silencer Cut tab 1 off exhaust end section 3 2 Cutting point Preparing exhaust end section Vehicles with daytime running light 1 M6x12 bolt spring lockwasher 2 Hose clamp 3 Exhaust end section Mounting silencer and end section 34 1 2 3 35 1 2 3 4 5 36 2 3 1 ...

Страница 18: ...ncer at position 1 must be observed Aligning si lencer Vehicles with front fog light Ensure sufficient distance from neighbouring components correct if necessary C204 S204 and W204 Slide incomplete exhaust end section 3 onto exhaust silencer 5 mm distance between end section 3 and silencer align and fasten X204 Slide complete exhaust end section 3 onto exhaust silencer 1 M6x12 bolt spring lockwash...

Страница 19: ...l line and wiring harness with rub protection on sharp edges WARNING The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness rout ing diagram Complete connector of metering pump after routing Pin assignment is not relevant 1 Connector housing 2 Lock 3 Blue brown bl br wires 4 Coding 5 Timer lock Disman tling con nector 1 9 mm dia corrugated tube wiring har n...

Страница 20: ...esive surface for adhesive base 1 1 Adhesive base 2x cable tie 2x 2 Corrugated tube 3 Cable tie existing hole Routing lines Degrease adhesive surface for adhesive base 1 1 Adhesive base 2x cable tie 2x 2 Fuel line wiring harness of metering pump Routing lines Distribute retaining clamps 1 10x evenly along vehicle underbody and insert fuel line 2 and wiring harness of metering pump Routing lines 43...

Страница 21: ... Pump C204 S204 and W204 Drill 9 1 mm dia hole 1 mount M6 rivet nut Rivet nut for meter ing pump Degrease adhesive surface for adhesive base 4 1 M6x25 bolt 2 Wiring harness of metering pump con nector mounted 3 90 moulded hose 10 mm dia clamp 2x fuel line 4 Adhesive base cable tie 5 Mounting of metering pump 6 Metering pump Mounting metering pump X204 Drill 9 1 mm dia hole 1 mount M6 rivet nut Riv...

Страница 22: ...p 80L Fuel Tank Metering Pump Angle down perforated bracket 1 and drill hole at position 2 to 8 5mm dia Preparing perforated bracket 1 M6x25 bolt flanged nut 2 Mounting of metering pump 3 Metering pump 4 Cable tie 5 Perforated bracket 6 180 moulded hose 10 mm dia clamp Premount ing meter ing pump Mount perforated bracket on original vehicle bolt of fuel tank fastening Paste insulation strip 4 1 Wi...

Страница 23: ... traction Cut standpipe 1 at an angle 2 Section discard Cutting standpipe to size Observe tightening torque 5 Nm of flanged nut 6 on fuel standpipe 7 Mount 3 5 mm dia moulded hose 4 on fuel standpipe 7 1 Fuel tank sending unit 2 Standpipe 3 10 mm dia clamp 5 8 mm dia clamp Mounting fuel stand pipe Mount fuel tank sending unit 4 in accordance with manufacturer s instructions Mount 3 5 mm dia hose 1...

Страница 24: ...from lower section 2 in accordance with manufacturer s instruc tions Fuel ex traction Cut off connection piece 3 flush on underside 1 Drill 6mm dia hole 2 centred in the inner sur face of the fuel tank sending unit Fuel ex traction Insert fuel standpipe 1 in upper section of fuel tank sending unit 2 Fuel ex traction Observe tightening torque 5 Nm of flanged nut 2 on fuel standpipe 1 Fuel ex tracti...

Страница 25: ...m dia moulded hose 3 2 10 mm dia clamp Premount ing stand pipe Attach premounted standpipe 3 on fuel stand pipe 1 and secure with 8 mm dia clamp 2 4 Fuel tank sending unit Mounting standpipe Mount fuel tank sending unit 1 in accordance with manufacturer s instructions Insert line holder 3 for guiding standpipe 2 in lower section of fuel tank sending unit 4 Mounting standpipe 62 1 2 160 63 2 3 1 64...

Страница 26: ...p 5 10 mm dia clamp 6 Fuel line 7 6x11 hose rattle protection Mounting wire Diesel Fuel Standpipe Remove fuel tank sending unit 1 in accord ance with manufacturer s instructions Watch drilling chips while drilling 2 6 mm dia hole Fuel ex traction Insert fuel standpipe 2 into fuel tank sending unit 1 Fuel ex traction Observe tightening torque 5 Nm of flanged nut 1 on fuel standpipe 3 2 Fuel tank se...

Страница 27: ... dia moulded hose 4 on fuel standpipe 6 1 Fuel tank sending unit 2 Standpipe 3 10 mm dia clamp 5 8 mm dia clamp Mounting standpipe Mount fuel tank sending unit 3 in accordance with manufacturer s instructions Mount 90 moulded hose 2 with 3 5mm dia on fuel standpipe 5 1 10 mm dia clamp 4 8 mm dia clamp 6 6x11 hose rattle protection 7 Fuel line Mounting fuel line 70 2 1 155 71 1 5 2 3 4 6 72 4 2 3 5...

Страница 28: ...6 1 Metering pump 2 10 mm dia clamp 3 90 moulded hose 4 10 mm dia clamp 5 Fuel line 6 Cable tie adhesive base Connect ing meter ing pump X204 Degrease adhesive surface for adhesive base 2 1 90 moulded hose 10 mm dia clamp 2 Cable tie adhesive base 3 Fuel line Connect ing meter ing pump 80l fuel tank 1 10 mm dia clamp 2 Fuel line 3 180 moulded hose Connect ing meter ing pump 73 1 3 6 2 4 5 74 3 2 1...

Страница 29: ...tall hoses so that they are kink free Unless specified otherwise always fasten using cable ties Position clamps so that other hos es cannot be damaged When installing the hoses the heater must be filled with coolant The connection should be inline based on the following diagram Hose rout ing dia gram Non designated spring clips 25 mm dia 1 Original vehicle spring clip 2x 2 Black sw rubber isolator...

Страница 30: ...utting hoses to length Slide braided protection hoses on to hoses A and B and cut to length Cut heat shrink plastic tubing to size 1 Heat shrink plastic tubing length 50 4x Preparing hoses Detach pass through 1 at the marking and re move Removing pass through Turn original vehicle spring clip 1 2x as shown Aligning clamps A B X X B A 1 1 1 1 76 1 77 1 1 ...

Страница 31: ...ermo Comfort SE 31 Cut out corrugated tube 1 according to length and slide onto brake line Mounting corrugated tube 1 Battery carrier 2 200mm edge protection Mounting edge pro tection 1 8 mm dia hole Hole in guard plate 1 Hose bracket 2 fold can be locked Inserting hose bracket 78 1 1 79 1 2 80 1 81 1 ...

Страница 32: ...lips will be reused Cutting point 1 Original vehicle spring clip 2 Connection piece on engine outlet Connect ing engine outlet Route hose A into hose bracket 1 and route forward through pass through Routing in engine compart ment Insert hose bracket 1 between hose A and the coolant pipe of the heat exchanger outlet lying under it Routing in engine compart ment 82 1 83 A 2 1 84 A 1 85 A 1 ...

Страница 33: ...ting pump Connec tion of heater inlet 1 Connection piece on heat exchanger in let 2 Original vehicle spring clip Connect ing heat ex changer inlet Route hose B into hose bracket 1 and route forward through pass through Close lock Routing in engine compart ment 1 Battery carrier mounted Routing in engine compart ment 86 1 A 87 B 1 2 88 A B 1 89 A B 1 ...

Страница 34: ...nt No 1315959G_EN Status 31 01 2013 Webasto Thermo Comfort SE 34 Slide black sw rubber isolator 1 onto hose B Routing in engine compart ment 1 Connection piece on heater outlet 2 Align black sw rubber isolator Connec tion of heater out let 90 B 1 A 91 1 2 B ...

Страница 35: ... Comfort SE 35 Combustion Air Discard section X 1 Combustion air pipe a 480 Cutting combus tionairpipe to length 1 Perforated bracket Angling down per forated bracket 1 Original vehicle bolt 2 Angle bracket Mounting angle bracket 1 Combustion air pipe Mounting combus tion air pipe a 1 X 90 80 1 92 1 2 93 1 ...

Страница 36: ... GLK Class X204 Ident No 1315959G_EN Status 31 01 2013 Webasto Thermo Comfort SE 36 1 Combustion air pipe 2 Cable tie Routing combus tion air pipe 1 51 mm dia p clamp 2 Silencer 3 M5x20 bolt flanged nut Mounting silencer 94 1 1 2 95 1 2 3 ...

Страница 37: ...The exhaust end section 1 must be centred relative to the hole 1 and aligned flush with the wheel well inner panel 2 realign exhaust end section 1 if necessary Aligning exhaust end section X204 Drill 45 mm dia hole 1 in trim 2 The exhaust end section 3 must be centred relative to the hole 1 and aligned flush with the trim 2 realign exhaust end section 3 if necessary 3 Exhaust end section Aligning ...

Страница 38: ... and bleed the coolant circuit according to the vehicle manufacturer s specifications Teach Telestart according to Installation documentation T91 T100 HTM adjust digital timer if necessary Activate push button according to Installation documentation T91 T100 HTM Reposi tioning of switch input Define settings of A C control panel according to the operating and maintenance instruc tions of TT Evo Mo...

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